Articles of footwear with uppers comprising a wound component and methods of making the same

ABSTRACT

Articles of footwear and methods of making articles of footwear including one or more continuous threads wound around anchor points. The winding of the one or more continuous threads forms a thread pattern that imparts desired characteristics to components of the article of footwear. Thread lines of the thread pattern may be bonded together. In some embodiments, thread lines may be bonded with a bonding layer.

FIELD

The described embodiments generally relate to articles of footwear andmethods of making articles of footwear. In particular, describedembodiments relate to articles of footwear with uppers including acomponent made by winding a continuous thread into a thread pattern.

BACKGROUND

Individuals are often concerned with the durability, weight, and/orcomfort of an article of footwear. This is true for articles of footwearworn for non-performance activities, such as a leisurely stroll, and forperformance activities, such as running. Durable footwear will properlyfunction for an extended period of time. Lightweight footwear minimizesthe weight an individual has to carry on his or her feet and may becomfortable for an individual. Customized footwear may increase comfortfor an individual because it is tailored to the individual's footanatomy.

For some individuals, for example athletes, stability and propulsion maybe desired characteristics for an article of footwear. Footwear thatfacilitates propulsion (e.g., forward and/or upward motion) may help anathlete perform at an optimal athletic level. Stability for footwear, anin particular stability in portions supporting the ankles of anindividual, may reduce the chance of injury to the individual's feet.

Proper footwear should be durable, comfortable, and provide otherbeneficial characteristics for an individual. Therefore, a continuingneed exists for innovations in footwear and components used tomanufacture the footwear.

BRIEF SUMMARY OF THE INVENTION

Some embodiments are directed to a method of making an upper for anarticle of footwear, the method including defining a plurality ofperipheral anchor points; winding a continuous thread around theplurality of peripheral anchor points to form a thread pattern, thecontinuous thread including a plurality of thread lines with each threadline extending between two respective peripheral anchor points; andbonding the continuous thread at a point of intersection between thethread lines.

Some embodiment are directed to a method of making an upper for anarticle of footwear, the method including winding a continuous threadaround a set of pins to form a thread pattern, the pins being coupled toand extending from a support structure and disposed at locationscorresponding to a perimeter of the upper, and the continuous threadincluding a plurality of thread lines, where each thread line extendsbetween two respective pins; and bonding the continuous thread to itselfat one or more of the plurality of pins.

Some embodiments are directed to an article of footwear including asole; and an upper coupled to the sole, the upper including a pluralityof anchor points disposed along a perimeter of the upper, and acontinuous thread fixed at the plurality of anchor points and includinga plurality of thread lines with each thread line extending between tworespective anchor points, where the anchor points have a thread linecommunication number of three or more, and where the continuous threadis bonded at the plurality of anchor points.

Some embodiments are directed to an article of footwear including asole; and an upper coupled to the sole, the upper including a perimeterlayer including an outer edge and an inner edge, a first plurality ofthread line groups including three or more thread lines extendingradially from respective areas on the outer edge, and a second pluralityof thread line groups including three or more thread lines extendingradially from respective areas on the inner edge, where the thread linesof the first plurality of thread line groups and the thread lines of thesecond plurality of thread line groups are bonded to each other atpoints of intersection between the thread lines.

Some embodiments are directed to a method of making an article offootwear, the method including winding a continuous thread around a setof pins to form a thread pattern for an upper of the article offootwear, the pins coupled to and extending from a support structure anddisposed at locations corresponding to a perimeter of the upper, and thecontinuous thread comprising a plurality of thread lines, where eachthread line extends between two respective pins; and bonding thecontinuous thread to itself at one or more of the plurality of pins.

BRIEF DESCRIPTION OF THE DRAWINGS/FIGURES

FIG. 1A shows an article of footwear according to some embodiments.

FIG. 1B shows the upper of FIG. 1A.

FIG. 2 is an exemplary flowchart of a method of according to someembodiments.

FIG. 3 shows a thread pattern and a pin assembly plate according to someembodiments.

FIG. 4A shows a side view of a thread pattern and a three dimensionalpin assembly object according to some embodiments.

FIG. 4B shows a perspective view the thread pattern and the threedimensional pin assembly object of FIG. 4A.

FIG. 5 shows a thread pattern with cushioning elements according to someembodiments.

FIG. 6 shows a thread pattern with a bonding layer according to someembodiments.

FIG. 7 shows an article of footwear according to some embodiments.

FIG. 8A shows a thread model according to some embodiments.

FIG. 8B shows a thread model according to some embodiments.

FIG. 8C shows a thread model according to some embodiments.

FIG. 8D shows a thread model according to some embodiments.

FIG. 9A shows a thread pattern according to some embodiments.

FIG. 9B shows a thread pattern according to some embodiments.

FIG. 10 shows a bottom perspective view of an upper according to someembodiments.

FIG. 11 shows a bottom view of a sole according to some embodiments.

FIG. 12A shows a perspective view of pin assembly plate according tosome embodiments.

FIG. 12B shows a side view of the pin assembly plate of FIG. 12A in afirst position.

FIG. 12C shows a side view of the pin assembly plate of FIG. 12A in asecond position.

FIG. 13 shows a robotic arm for producing thread patterns according tosome embodiments.

FIG. 14A shows a thread pattern and a frame according to someembodiments.

FIG. 14B shows the frame of FIG. 14A with a portion of the threadpattern removed.

FIG. 15 shows a thread swatch according to some embodiments.

FIGS. 16A and 16B show a thread swatch according to some embodiments.

FIG. 17 shows a thread swatch according to some embodiments.

FIG. 18 shows a thread swatch according to some embodiments.

FIG. 19 shows a thread swatch according to some embodiments.

FIGS. 20A-20C show articles of footwear according to some embodiments.

FIG. 21A shows a mold according to some embodiments. FIG. 21B shows across-sectional view of a portion of FIG. 21A according to someembodiments along line 21B-21B.

FIGS. 22A-22C illustrate a method of making a sole according to someembodiments.

FIG. 23 shows an illustration of an individual with sensor modulescoupled to articles of footwear according to some embodiments.

FIG. 24A shows an exemplary strain data map. FIG. 24B shows a threadpattern based on the strain data map of FIG. 24A.

FIGS. 25A-25N illustrate bonding methods according to variousembodiments.

FIG. 26 shows a schematic block diagram of an exemplary computer systemin which embodiments may be implemented.

DETAILED DESCRIPTION OF THE INVENTION

The present invention(s) will now be described in detail with referenceto embodiments thereof as illustrated in the accompanying drawings.References to “some embodiments”, “one embodiment”, “an embodiment”, “anexemplary embodiment”, etc., indicate that the embodiment described mayinclude a particular feature, structure, or characteristic, but everyembodiment may not necessarily include the particular feature,structure, or characteristic. Moreover, such phrases are not necessarilyreferring to the same embodiment. Further, when a particular feature,structure, or characteristic is described in connection with anembodiment, it is submitted that it is within the knowledge of oneskilled in the art to affect such feature, structure, or characteristicin connection with other embodiments whether or not explicitlydescribed.

An article of footwear has many purposes. Among other things, an articleof footwear may serve to provide cushioning for a wearer's foot, supporta wearer's foot, and protect a wearer's foot. Each of these purposes,alone or in combination, provides for a comfortable article of footwearsuitable for use in a variety of scenarios (e.g., exercise and every dayactivities). The features of an article of footwear (e.g., the materialsand components used to make footwear, and the way thesematerials/components are assembled in a manufacturing process) may bealtered to produce desired characteristics, for example, durability,support, weight, tackiness, texture, haptics, and/or breathability.

Durable footwear will properly function for an extended period of timeand may instill a wearer's trust in a specific manufacturer's footwear,leading to repeat sales. Supportive footwear may protect an individual'sfeet from injury. For example, an article of footwear configured toprovide ankle support may prevent injury to an individual's ankle byinhibiting undue twisting of the ankle. Lightweight footwear may beconformable for an individual, and for individuals competing in anathletic activity, such as running or biking, may provide a competitiveedge due to the decreased weight the individual carries on his or herfeet. Breathable footwear may increase comfort for an individual bywicking sweat and heat away from an individual's foot. Designingfootwear having a high degree of one or more of these characteristicswithout detrimentally affecting other characteristics of the footwearmay be desirable. Additionally, proper fitting footwear which adapts tothe wearer's foot or is correctly shaped to the wearer's foot mayprovide a benefit in comfort and stability, particularly during changesof direction. The proper zoning of areas of support, flexibility,stiffness, and softness may also benefit the wearer by more accuratelyproviding him or her desired characteristics of the footwear fordifferent movements, or different parts of their foot.

Propulsion enabled by an article of footwear may optimize theperformance of a wearer's foot by, for example, maximizing the energytransfer from the individual's foot to the surface his or her foot is incontact with (e.g., the ground), via the article of footwear. Maximizingthe energy transfer between the individual's foot and a surface (i.e.,reducing energy lost via and/or absorbed by an article of footwear) mayhelp an athlete, for example, accelerate faster, maintain a highermaximum speed, change directions faster, and jump higher. Designingfootwear having a high degree of propulsion without detrimentallyaffecting other characteristics of the footwear may be desirable.Providing tackiness in specific areas on an upper may tailor an upper toan individual's liking. For example, some soccer players may like asoccer boot that is smooth for ease of dribbling while others may likehigh friction for control during hard strikes.

An article of footwear, or a portion thereof (e.g., an upper), may beconfigured to provide various degrees of durability, support, weight,breathability, etc. But the cost of manufacturing the article offootwear may also be a consideration. Footwear, or a portion thereof,that may be manufactured at a relatively low cost may be desirable formanufacturers and consumers. Footwear that can be manufactured using arelatively small amount of resources (e.g., energy and man power),materials, and time reduces manufacturing costs and may also reduce theenvironmental impact of manufacturing.

Further, a manufacturing process that facilitates the manufacture ofcustomized footwear without increasing the complexity of themanufacturing process may be desirable. Customizing an article offootwear, or a portion thereof (e.g., an upper), for a particularindividual or a group of individuals having similar foot anatomies(e.g., foot size and shape) may provide proper support and increasedcomfort for an individual. Also, it may allow an individual to order/buyarticles of footwear customized to his or her needs. Moreover, it mayallow the individual to order/buy new and/or replacement articles offootwear customized to his or her needs when desired.

The articles of footwear discussed herein include a component, forexample an upper or a sole, made by winding one or more continuousthreads into a desired thread pattern. In some embodiments, thecontinuous thread(s) may be wound around and between fixed anchorpoints. In some embodiments, the continuous thread(s) may be woundaround and between moveable anchor points. Winding the continuousthread(s) around the anchor points includes wrapping a continuous threadaround a first anchor point, extending that continuous thread to asecond anchor point, wrapping that continuous thread around the secondanchor point, and so on. The number and position of the anchor pointsmay be utilized to control characteristics of the thread pattern, andtherefore the article of footwear component. Also, the number of times acontinuous thread is wound from anchor point to anchor point may beutilized to control characteristics of the thread pattern, and thereforethe article of footwear component.

Continuous thread(s) of a thread pattern may be bonded within the threadpattern. The bonding of continuous thread(s) of a thread pattern mayconsolidate the thread pattern and fix thread lines in a wound pattern.In some embodiments, bonding continuous thread(s) of a thread patternmay be utilized to control characteristics of the thread pattern. Insome embodiments, a continuous thread may be bonded to itself within athread pattern. In some embodiments, a continuous thread may be bondedto itself at one or more anchor points of a thread pattern. In someembodiments, a continuous thread may be bonded to itself at points ofoverlap between different thread lines of the continuous thread (i.e.,at thread line intersection points). In some embodiments, differentcontinuous threads of a thread pattern may be bonded together. In someembodiments, different continuous threads may be bonded to each other atone or more anchor points of a thread pattern. In some embodiments,different continuous threads may be bonded to each other at points ofoverlap between the different continuous threads (i.e., at intersectionpoints between the different continuous threads). The bonding ofcontinuous thread(s) may fix the continuous thread(s) in tension as thethread(s) are wound around anchor points in tension. The bonding ofthread(s) in tension allows a thread pattern to contract once removedfrom anchor points used to wind the thread pattern, which may beutilized to control characteristics of the thread pattern.

In some embodiments, a plurality of different continuous threads may bewound around anchor points to form a thread pattern. In someembodiments, different continuous threads may be wound in the sameconfiguration (i.e., around the same anchor points and along the samepaths). In some embodiments, different continuous threads may be woundin different configurations (i.e., around one or more different anchorpoints and/or along different paths between one or more anchor points).Different continuous threads may define different wound layers for anfootwear component. And these different layers may provide differentcharacteristics for a thread pattern, and therefore the footwearcomponent.

Continuous thread(s) may be wound around anchor points in variousconfigurations to provide varying degrees of characteristics for anarticle of footwear component. The number of anchor points, the positionof the anchor points, and/or the way continuous threads are wound aroundthe anchor points may be utilized to produce a footwear componentshaving desired characteristics, such as strength, support, propulsion,breathability, comfort, tackiness, abrasion resistance, fit, texture,haptics, and durability. Characteristics of a footwear component can bevaried by changing the arrangement of anchor points and/or the waycontinuous thread(s) are wound around the anchor points. Characteristicscan also be varied by altering the material of continuous thread(s).

In some embodiments, when winding continuous threads for an upper, theanchor points may be peripheral anchor points arranged in positionscorresponding to a perimeter of an upper, or a portion of an upper, foran article of footwear. Winding a continuous thread around and betweenthe peripheral anchor points may define the perimeter shape of theupper, or portion of an upper. And the way continuous thread(s) arewound between respective peripheral anchor points (i.e., the windingpath for the continuous thread(s)) can be leveraged to produce an upperhaving desired characteristics.

Winding continuous thread(s) as described herein may facilitatecustomization of an article of footwear component for an individual, orgroup of individuals. The location of anchor points, the number andconfiguration of continuous threads wound around the anchor points, andthe material of the continuous thread(s) may be tailored for anindividual, or group of individuals. Customization via tailoring of awound thread pattern may facilitate flexible and efficient manufacturingby reducing the number of changes in a manufacturing process needed tocustomize a footwear component (e.g., an upper) for an individual, orgroup of individuals. For example, in some embodiments, theconfiguration of a single continuous thread within a thread pattern, maybe the only parameter altered between uppers for different individuals,or groups of individuals. A change in the configuration of a continuousthread within a thread pattern may alter, for example, the strength,support, propulsion, breathability, comfort, tackiness, abrasionresistance, texture, haptics, and/or durability for different areas onan upper.

In some embodiments, the thread pattern for wound continuous thread(s)may be based on a biometric data profile for an individual, or group ofindividuals. In some embodiments, the number and/or location of anchorpoints be based on a biometric data profile for an individual, or groupof individuals. In some embodiments, the number and configuration ofcontinuous threads within a thread pattern may be based on a biometricdata profile for an individual, or group of individuals. In someembodiments, the material of different continuous threads within athread pattern may be based on a biometric data profile for anindividual, or group of individuals. Tailoring a thread pattern bytailoring anchor point locations, wound thread configurations, and/ormaterials of continuous threads may provide a footwear component (e.g.,upper) with desired support, stability, durability, weight, propulsion,abrasion resistance, tackiness, and/or breathability for an individual,or group of individuals.

FIGS. 1A and 1B show an article of footwear 100 and upper 120 accordingto some embodiments. Article of footwear 100 may include upper 120coupled to a sole 180. Article of footwear 100 and upper 120, include aforefoot end 102, a heel end 104, a medial side 106, and a lateral side108 opposite medial side 106. As illustrated in FIG. 1B, upper 120includes a forefoot portion 110, a midfoot portion 112, and a heelportion 114. Portions 110, 112, and 114 are not intended to demarcateprecise areas of upper 120. Rather, portions 110, 112, and 114 areintended to represent general areas of upper 120 that provide a frame ofreference. Although portions 110, 112, and 114 are illustrated inconnection with upper 120 in FIG. 1B, references to portions 110, 112,and 114 also may apply specifically to article of footwear 100 or sole180, or individual components of article of footwear 100 or sole 180.

Upper 120 may be formed of one or more components that are stitched,bonded, or otherwise joined together to form a structure for receivingand securing a foot relative to sole 180. And upper 120 includes a leasta portion defined by a thread pattern 122. Thread pattern 122 is made bywinding one or more continuous threads into a thread pattern asdiscussed herein. Thread pattern 122 is not a knitted or woven pattern.Thread pattern 122 may be referred to as a thread network of adjacentand overlapping thread lines. In some embodiments, thread pattern 122may include a network of individual thread lines that form asubstantially continuous material with minimal void space between threadlines. As used herein, “void space” means an opening extending through athread pattern between thread lines of the thread pattern. In someembodiments, the substantially continuous material may have a ratio(V:T) of void space (V) to thread material (T) of at least 1:1 measuredacross all or a portion of an outer surface of a thread pattern. In someembodiments, the ratio of void space to thread material may be at least1:1, 1:2, 1:2.5, 1:3, 1:4, 1:5, 1:6, 1:7, 1:8, 1:9, 1:10, 1:20, 1:50, or1:100. In some embodiments, a thread pattern may include a network ofthread lines that form a continuous material with no void space betweenthread lines. A ratio of void space to thread material may be measuredfor a thread pattern before or after bonding of thread lines. In someembodiments, bonding of thread lines may serve to reduce the amount ofvoid space of a thread pattern. For example, thermally bonding threadlines via a polymer material of the thread lines may reduce the amountof void space by filling in void space with thermally melted polymermaterial. FIGS. 20A-20C illustrate thread patterns 122 having minimalvoid space across the entire thread pattern according to someembodiments.

Thread pattern 122 may wrap around all or a portion of the sides, thetop, and/or the heel of a wearer's foot. In some embodiments, threadpattern 122 may wrap around at least a portion of the bottom (i.e., thesole) of a wearer's foot when worn. For example, an upper with threadpattern 122 may wrap the sole of a wearer's foot when worn (see e.g.,thread pattern 1002 in FIG. 10). As another example, thread pattern 122may wrap around the sole of a wearer's foot by wrapping around a solefor an article of footwear. In other words, thread pattern 122 may formall or a portion of a thread pattern for upper 120 and a sole (e.g.,thread pattern 1120 of sole 1100).

Upper 120 may extend along the lateral side of the foot, along themedial side of the foot, over the foot, around a heel of the foot,and/or under the foot. Upper 120 defines a void 155, which is agenerally hollow area that has the general shape of a foot and isconfigured to receive the foot. An opening of void 155 may be defined inwhole or in part by a collar 156 located in at least heel portion 114 ofupper 120.

In addition, upper 120 includes a throat area 150 extending from collar156 towards forefoot portion 110 of upper 120. Throat area 150 extendsover a dorsal area of a wearer's foot that corresponds generally to thelocation of a wearer's cuneiform and metatarsal bones. In someembodiments, throat area 150 may define a portion of the opening of void155 to assist a wearer in inserting and removing his or her foot fromvoid 155. In some embodiments, throat area 150 may define an opening fora tongue 154 that extends between lateral and medial perimeter sides ofthroat area 150 and moveably opens and closes a portion of void 155 toenhance the adjustability of footwear 100. In some embodiments, throatarea 150 may be a “tongue-less” throat area 150.

Upper 120 may also include one or more eyelets 152 formed in a perimeterportion of throat area 150 for securing and tensioning a shoe lace. Insome embodiments, eyelets 152 may be integrally formed during formationof upper 120. In some embodiments, eyelets 152 may be separatecomponents coupled to upper 120 via, for example, stitching or anadhesive. A shoe lace may extend through the eyelets 152 and permits awearer to adjust dimensions of upper 120 to accommodate his or her foot.More particularly, the shoe lace may allow a wearer to tighten or loosenupper 120 around his or her foot. In addition to or alternative toeyelets 152, upper 120 may include other lace-receiving elements, suchas loops or hooks.

In some embodiments, upper 120 may include a heel counter 158. Heelcounter 158 provides cushioning, support, and/or protection for awearer's heel and/or Achilles tendon. In some embodiments, heel counter158 may be a separate piece attached to the reminder of upper 120 via,for example, stitching and/or an adhesive. In some embodiments, heelcounter 158 may be an integral component of upper 120. In other words,heel counter 158 may be formed in the same manner as other components ofupper 120 (e.g., via a winding process as discussed herein).

With reference to FIG. 1A, for example, upper 120 is coupled to sole 180at a biteline 160 (i.e., a sole connection area). Together, biteline160, collar 156, heel counter 158, and a perimeter portion of throatarea 150 may define a perimeter portion 162 of upper 120. Perimeterportion 162 may include an outer edge defined by biteline 160 and aninner edge defined by collar 156 and a perimeter of throat area 150.Perimeter portion 162 may be a define a frame having a shapecorresponding to at least a portion of a perimeter shape of upper 120.Portions of upper 120 within perimeter portion 162 include the quarterpanels, vamp portion, and toe box portion of upper 120. Thread pattern122 may define all or a portion of perimeter portion 162 and/or anyportion of upper 120 within perimeter portion 162 of upper.

In some embodiments, upper 120 may include a fabric layer 172 disposedon the outer surface and/or the inner surface of thread pattern 122. Asused herein, the term “outer surface” or “outer side” refers to thesurface of a component that faces away from the foot when worn by awearer. And “inner surface” or “inner side” refers to the surface of acomponent that faces toward the foot when worn by a wearer.

In some embodiments, fabric layer 172 may be a woven, non-woven, orknitted polymeric layer. In some embodiments, fabric layer 172 may be awoven, non-woven, or layer composed of thermoplastic polyurethane (TPU),polyester, polyamide, polyethylene (PE), PE foam, polyurethane (PU)foam, and co-polymers or polymer blends including one or more thesepolymers. In some embodiments, fabric layer 172 may be a bioengineeredwoven, knitted or layered synthetic spider silk, woven, knitted orlayered plant based materials, or woven, knit or layered recycled and/orextruded plastics. In some embodiments, fabric layer 172 may be film orsheet of a polymeric material, such as thermoplastic polyurethane (TPU),polyester, polyamide, polyethylene (PE), PE foam, polyurethane (PU)foam, and co-polymers or polymer blends including one or more thesepolymers. In some embodiments, fabric layer 172 may include a pluralityof layers stacked vertically and/or arranged side-by-side. In someembodiments, the plurality of layers may be laminated. In someembodiments, fabric layer 172 may be a woven, non-woven, or knittedlayer for providing cushion and/or thermal insulation for article offootwear 100. In some embodiments, fabric layer 172 may be a sockbootie.

Upper 120 and sole 180 may be configured for a specific type offootwear, including, but not limited to, a running shoe, a hiking shoe,a water shoe, a training shoe, a fitness shoe, a dancing shoe, a bikingshoe, a tennis shoe, a cleat (e.g., a baseball cleat, a soccer cleat, ora football cleat), a basketball shoe, a boot, a walking shoe, a casualshoe, or a dress shoe. Moreover, sole 180 may be sized and shaped toprovide a desired combination of cushioning, stability, and ridecharacteristics to article of footwear 100. The term “ride” may be usedherein in describing some embodiments as an indication of the sense ofsmoothness or flow occurring during a gait cycle including heel strike,midfoot stance, toe off, and the transitions between these stages. Insome embodiments, sole 180 may provide particular ride featuresincluding, but not limited to, appropriate control of pronation andsupination, support of natural movement, support of unconstrained orless constrained movement, appropriate management of rates of change andtransition, and combinations thereof.

In some embodiments, sole 180 may include traction elements, such ascleats 182. In some embodiments, sole 180 may include a midsole coupledto an outsole. For example, in reference to FIG. 7, sole 180 may be sole780 including midsole 782 and outsole 784. Sole 180 and portions thereof(e.g., midsole 782 and outsole 784) may comprise material(s) forproviding desired cushioning, ride, and stability. Suitable materialsfor sole 180 (midsole 782 and/or outsole 784) include, but are notlimited to, a foam, a rubber, ethyl vinyl acetate (EVA), expandedthermoplastic polyurethane (eTPU), expandable polyether block amide(ePEBA), thermoplastic rubber (TPR) and a thermoplastic polyurethane(TPU). In some embodiments, the foam may comprise, for example, an EVAbased foam or a PU based foam and the foam may be an open-cell foam or aclosed-cell foam. In some embodiments, midsole 782 and/or outsole 784may comprise elastomers, thermoplastic elastomers (TPE), foam-likeplastics, and gel-like plastics.

In some embodiments, portions of sole 180 (e.g., midsole 782 and outsole784) may comprise different materials to provide differentcharacteristics to different portions of sole 180. In some embodiments,midsole 782 and outsole 784 may have different hardness characteristics.In some embodiments, the material density of midsole 782 and outsole 784may be different. In some embodiments, the moduli of the materials usedto make midsole 782 and outsole 784 may be different. As a non-limitingexample, the material of outsole 784 may have a higher modulus than thematerial of midsole 782.

Sole 180 and portions thereof (e.g., midsole 782 and outsole 784) may beformed using suitable techniques, including, but not limited to,injection molding, blow molding, compression molding, and rotationalmolding. In some embodiments, midsole 782 and outsole 784 may bediscrete components that are formed separately and attached. In someembodiments, midsole 782 may be attached to outsole 784 via, forexample, but not limited to, adhesive bonding, stitching, welding, or acombination thereof. In some embodiments, midsole 782 may be attached tooutsole 784 via an adhesive disposed between midsole 782 and outsole784.

As shown in FIGS. 1A and 1B, upper 120 includes thread pattern 122. Allor a portion of upper 120 may include thread pattern 122. In someembodiments, thread pattern 122 may be a single thread structuredefining at least a portion of upper 120. In some embodiments, threadpattern 122 may include a plurality of thread structures coupledtogether to define at least a portion of upper 120.

Thread pattern 122 may include a plurality of anchor points 134 and acontinuous thread 130 fixed at a plurality of anchor points 134. In someembodiments, anchor points 134 may be disposed along a perimeter ofupper 120 (e.g., in perimeter portion 162). Such anchor points 134 maybe referred to as “peripheral anchor points.” As used herein, “thread”means a material having a length that is substantially larger than itswidth. A “thread” may be a filament, a fiber, a yarn, a knitted element,a cable, a cord, a fiber tow, a tape, a ribbon, a monofilament, a braid,a string, and other forms of materials which can be spooled and laiddown with the same technique.

As used herein, “anchor point” means a location to which a thread orgroup of thread lines is fixedly attached. A thread or thread line maybe wrapped, wound, bonded, or otherwise attached at an anchor point. Ananchor point may be a location on an upper (e.g., anchor points 134).For example, an anchor point may be a hole or opening left behind by astructure (e.g., pin, projection, or nub) used to wind continuousthread(s) of a thread pattern. In some embodiments, a thread pattern foran upper may not include any anchor point locations because all theanchor point locations present during winding of the thread pattern havebeen removed (e.g., cut off the thread pattern). An anchor point mayalso be a structure (e.g., pin, projection, or nub) used to windcontinuous thread(s) of a thread pattern. And the anchor point structuremay or may not form a portion of a thread pattern for an upper. Forexample, a thread pattern for an upper may be removed from anchor pointsdefined by metal pins, but anchor points defined by pins composed of ameltable material may be present in a thread pattern for an upper (afterbeing melted and re-solidified).

Continuous thread 130 may be wrapped around a plurality of anchor points134 and includes a plurality of thread lines 132. Each thread line 132extends between two respective anchor points 134. Continuous thread(s)130 may be wrapped around a plurality of anchor points 134 in tensionsuch that individual thread lines 132 are in tension when wrapped aroundanchor points 134. In some embodiments, different continuous threads 130and/or thread lines 132 may be wrapped around anchor points 134 atdifferent tensions to impart desired characteristics to thread pattern122. By winding continuous(s) threads 130 in tension, thread pattern 122may bonded while thread lines 132 are under tension such that threadlines 132 are in tension in a bonded thread pattern 122. Bonding threadlines 132 while thread lines 132 are under tension fixes the threadlines 132 in tension within thread pattern 122. Fixing thread lines 132in tension will result in thread lines 132 wanting to contract whenremoved from anchor points used to wind thread pattern 122. In caseswhere a portion of a thread line 132 is not bonded in a fully fixedposition, the thread line 132 may contract when removed anchor points.In such embodiments, the portion(s) of the thread line 132 that is/arefixed during a bonding process will be under tension while the otherportion(s) will be free to contract, and thus will not be under tensionin thread pattern 122. In embodiments where different thread lines 132were wound at different tensions, different thread lines 132 of threadpattern 122 will be under different values of tension in thread pattern122. The tension of thread lines 132 may be utilized to controlcharacteristics of thread pattern 122, and therefore upper 120.

The number of thread lines 132 fixed at an anchor point 134 is definedby the “thread line communication number” of an anchor point 134. Asused herein, “thread line communication number” means the number ofthread lines extending from an anchor point to different anchor points.Two thread lines extending between the same two anchor points (i.e.,overlaying thread lines) only counts as “1” for purposes of calculatinga thread line communication number for the anchor points. For example, athread line communication number of five means that an anchor point hasfive thread lines extending from it with each of the five thread linesleading to another, different anchor point. As another example, a threadline communication number of six means that an anchor point has sixthread lines extending from it with each of the six thread lines leadingto another, different anchor point.

Anchor points 134 may have a thread line communication number of “X” ormore for continuous thread 130. In some embodiments, two or morerespective anchor points 134 may have a thread line communication numberof “X” or more. In some embodiments, all the anchor points 134 of threadpattern 122 may have a thread line communication number of “X” or more.“X” may be, for example, two, three, four, five, six, seven, eight,nine, ten, or within a range having any two of these values as endpoints. For example, as show in FIG. 1B, anchor point 134(a) has athread line communication number of six and anchor point 134(b) has athread line communication number of seven.

Thread lines 132 may be bonded at anchor points 134. Thread lines 132may be bonded at anchor points 134 via an adhesive, a bonding layer,thermal (conductive or convective) heat (e.g., in a heat press or oven),IR (infrared) heating, laser heating, microwave heating, steam, amechanical fastener (e.g., a clip), hook and loop fasters,needle-punching, hydro-entanglement, ultrasonic/vibratory entanglement,felting, knotting, or by pushing one thread line through the otherthread line(s). In some embodiments, thread lines 132 may be directlybonded together at anchor points 134 (e.g., via the polymeric materialof continuous thread 130). In some embodiments, thread lines 132 may bedirectly bonded together at perimeter portion 162 via the polymericmaterial(s) of continuous thread 130. For example, heat and pressure maybe applied to perimeter portion 162 of upper 120 to directly bond threadlines 132 in perimeter portion, and at any peripheral anchor points 134within perimeter portion 162. In embodiments including direct bonding ofthread lines 132 at a perimeter portion and/or anchor points, threadlines 132 are bonded at the perimeter portion and/or anchor pointswithout the use of an adhesive or bonding layer.

In some embodiments, thread lines 132 may be bonded together via abonding layer. In some embodiments, thread lines 132 may be bondedtogether at anchor points 134 (e.g., peripheral anchor points) via abonding layer. In such embodiments, the bonding layer is attached to oneor more anchor points 134 and mechanically couples the anchor point(s)134 to each other. The bonding layer may be, for example, a laminatedlayer, an adhesive layer, a stitched layer, a cured layer, or a screenprinted layer as described herein. In some embodiments, the laminationlayer, adhesive layer, cured layer, or screen printed layer may serve toencase anchor points 134 in a bonding layer. The bonding layer may bondthread lines 132 via any suitable mechanical bonding technique, forexample the bonding techniques discussed in regards to FIGS. 15-19. Insome embodiments, thread lines 132 may be bonded together without theuse of a bonding layer. For example, in some embodiments, thread lines132 may be directly bonded together via, for example, but not limitedto, local bonding via an adhesive, direct local bonding via material(s)of thread lines 132, needle punching, hydro-entanglement, andultrasonic/vibratory entanglement.

In some embodiments, the bonding layer may include a perimeter portiondefining all or a portion of perimeter portion 162. Perimeter portion162 illustrates a bonding layer in FIGS. 1A and 1B. Thread lines 132 mayextend radially from respective areas of perimeter portion 162. In someembodiments, the respective areas may be areas from which a group ofthread lines 132 extends radially (see e.g., groups 618 and areas 632 inFIG. 6). In some embodiments, the respective areas may be defined byanchor points 134. Thread lines 132 in a group of thread lines may bebonded to perimeter portion 162. The group of thread lines 132 extendingfrom a respective area may include a number “Z” of thread lines. In someembodiments, “Z” may be the same as “X.”

In some embodiments, thread lines 132 may be bonded at points wherethread lines 132 overlap in thread pattern (i.e., intersection points136). Thread lines 132 may be bonded at intersection points 136 via anadhesive, a bonding layer, thermal (conductive or convective) heat(e.g., in a heat press or oven), IR (infrared) heating, laser heating,microwave heating, steam, a mechanical fastener (e.g., a clip), hook andloop fasters, needle-punching, hydro-entanglement, ultrasonic/vibratoryentanglement, felting, knotting, or by pushing one thread line throughthe other thread line(s). In some embodiments, thread lines 132 may bedirectly bonded together at intersection points 136 (e.g., via thepolymeric material of continuous thread 130). In embodiments includingdirect bonding of thread lines 132 at intersection points 136, threadlines 132 are bonded at intersection points 136 without the use of anadhesive or bonding layer. In some embodiments, a bonding layer may bondthread lines 132 together at a plurality of intersection points 136within thread pattern 122. In embodiments including multiple continuousthreads, thread lines of respective continuous threads may be bonded atintersection points between the thread lines, either directly or via abonding layer.

Upper 120 may include a plurality of thread line groups including “Z” ormore thread lines 132 extending radially from respective areas on theouter edge of perimeter portion (e.g., extending radially from biteline160). Similarly, upper 120 may include a plurality of thread line groupsincluding “Z” or more thread lines 132 extending radially fromrespective areas on the inner edge of perimeter portion (e.g., extendingradially from collar 156 and a perimeter portion of throat area 150).

In some embodiments, continuous thread 130 includes overlaying threadlines 132. As used herein, “overlaying thread lines” means two or morethread lines that follow the same path between two respective anchorpoints. Overlaying thread lines need not be overlaid directly over eachother. Two or more thread lines are considered overlaying as long asthey extend between the same two anchor points. Thread pattern 122 mayinclude one or more continuous threads 130 with thread lines 132crossing over underlying thread line(s) 132 in various directions. Thethread lines 132 of thread pattern 122 may not be woven or knittedtogether. The thread lines 132 of thread pattern 122 may not beembroidered threads stitched to a base layer. Thread lines 132 may bethreaded over each other to form a thread network defining a patternedlayer for an article of footwear component.

In some embodiments, continuous thread 130 may be a polymer thread. Asused herein “polymer thread” means a thread composed at least in part ofa polymeric material. In some embodiments, a polymer thread may becomposed entirely of one or more polymeric materials. In someembodiments, a polymer thread may include a polymeric material coatedaround a core (which may or may not be composed of a polymericmaterial). In such embodiments, the core may be encapsulated by thecoating material. In some embodiments, a polymer thread may include anon-polymer core coated, covered, or encapsulated with a polymericmaterial. In some embodiments, a polymer thread may include a polymercore coated, covered, or encapsulated with a non-polymeric material. Insome embodiments, a polymer thread may be a braided thread with one ormore braids composed of a polymeric material. In some embodiments, thepolymeric material(s) of a polymer thread may be thermoplasticmaterial(s). In some embodiments, continuous thread 130 may be a threadcoated with an activatable adhesive, for example a heat activatedadhesive.

Suitable polymeric materials for polymer threads discussed hereininclude, but are not limited to, thermoplastic polyurethane (TPU), arubber, and silicone. In some embodiments, the TPU may be recycled TPU.In some embodiments, the polymeric material may be a photo-reactive(infra-red or ultraviolet light reactive) polymeric material, such as aphoto-reactive TPU. In some embodiments, the polymeric material may besoluble (e.g., water soluble). In embodiments including polymer threadswith a coated core, suitable materials for the core include, but are notlimited to, polyester, nylon, ultra-high molecular weight polyethylene(e.g., DYNEEMA® (a type of ultra-high molecular weight polyethylene)),carbon fiber, KEVLAR® (a type of para-aramid), bioengineered woven, knitor layered materials (e.g., synthetic spider silk), woven, knit orlayered plant based materials, knit or layered recycled and/or extrudedplastics, cotton, wool, and natural or artificial silk. In someembodiments, polymer threads may be thermoplastic polyurethane coatedpolyester threads produced by Sambu Fine Chemical Co., Ltd. of Korea. Insome embodiments, continuous thread 130 may be a non-polymer threadcomposed of non-polymer materials, such as carbon fiber, cotton, wool,or silk. In some embodiments, polymer threads may be a thermoplasticmelt yarn, polymer yarn with non-melt core, and other similar types ofyarn.

In some embodiments, upper 120, and thread pattern 122, includes morethan one continuous thread. For example, as shown in FIGS. 1A and 1B,thread pattern 122 includes a second continuous thread 170. Secondcontinuous thread 170 has the same or different characteristics as firstcontinuous thread 130. And second continuous thread 170 may beincorporated into thread pattern 122 in the same manner as firstcontinuous thread 130. Like first continuous thread 130, secondcontinuous thread 170 includes thread lines extending radially fromrespective areas of perimeter portion 162. In some embodiments, therespective areas may be areas from which a group of thread lines extendsradially (see e.g., groups 628 and areas 632 in FIG. 6). In someembodiments, the respective areas may be defined by anchor points 134.Also similar to continuous thread 130, thread lines in a group of threadlines may be bonded in perimeter portion 162 (e.g., via bonding layer ofperimeter portion 162).

Like continuous thread 130, continuous thread 170 may include aplurality of thread lines wound around and extending between tworespective peripheral anchor points 134. And anchor points 134 may havea thread line communication number of “Y” or more for second continuousthread 170. The thread line communication number for second continuousthread 170 may be the same as or similar to the thread linecommunication number for continuous thread 130. “Y” may be less than“X”, more than “X”, or the same as “X”.

In some embodiments, first continuous thread 130 may be composed of thesame material(s) as second continuous thread 170. In some embodiments,first continuous thread 130 may be composed of different material(s)than second continuous thread 170. The material(s) of differentcontinuous threads in a thread pattern may be selected to providetargeted characteristics to areas of a thread pattern, and therefore anupper. In embodiments including polymer thread(s) having a core coatedwith a polymeric material, the material of the core for differentcontinuous threads may be different or the same. And the material of thecore for different continuous threads may be selected to providetargeted characteristics to different areas of a thread pattern, andtherefore an upper. Similarly, for braided threads, the material(s) ofthe braided thread(s) may be selected to provide targetedcharacteristics to different areas of a thread pattern, and therefore anupper.

In some embodiments, continuous threads of a thread pattern may have adenier in the range of 1 denier to 3000 denier, including subranges. Forexample, continuous threads may have a denier of 1, 10, 50, 100, 200,300, 400, 500, 600, 700, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500,1600, 1700, 1800, 1900, 2000, 2100, 2200, 2300, 2400, 2500, 2600, 2700,2800, 2900, or 3000 denier, or within any range having any two of thesevalues as endpoints. In some embodiments, continuous threads of a threadpattern may have a denier in the range of 100 denier to 2000 denier. Insome embodiments, continuous threads of a thread pattern may have adenier in the range of 300 denier to 1200 denier.

In some embodiments, the denier of continuous thread(s) in a threadpattern may be selected to provide varying degrees of a characteristic(e.g., strength or stretchability) to different areas of the threadpattern. In embodiments including coated threads, the denier of the corematerial and/or the overall denier of the continuous thread(s) may beselected to provide varying degrees of a characteristic (e.g., strengthor stretchability) to different areas of a thread pattern. As anon-limiting example, a larger overall diameter or a larger corediameter for a given continuous thread may increase the degree ofdirectional strength imparted by the given continuous thread within athread pattern.

While FIGS. 1A and 1B show thread pattern 122 including two continuousthreads (130 and 170), thread pattern 122 may include any suitablenumber of continuous threads, such as for example, three, four, five,six, seven, eight, nine, ten, fifteen, or twenty continuous threads.Additional continuous threads may be the same as or different fromcontinuous threads 130 and 170. And additional continuous threads may beincorporated into thread pattern 122 in the same manner as continuousthreads 130 and 170. Additional continuous threads may be wound aroundand extended between anchor points 134 in the same fashion as continuousthreads 130 and 170.

In embodiments including a plurality of continuous threads, each woundcontinuous thread may define a layer of thread pattern 122. For example,a layer defined by wound continuous thread 130 may define a first layerof thread pattern 122 and a layer defined by wound continuous thread 170may define a second layer of thread pattern 122. And different layers ofa thread pattern may be disposed over each other in areas of overlapbetween the two layers. For example, a first layer defined by continuousthread 130 may be disposed over a second layer defined by continuousthread 170, or vice versa, in areas of overlap between the two layers.Different layers defined by different continuous wound threads mayprovide different characteristics to different areas of upper 120.

In some embodiments, one or more of the layers of thread pattern 122defined by a wound continuous thread may serve to bond other layers ofthread pattern 122 together. In such embodiments, these one or morelayers may be wound using a polymeric thread, which when heated, bondsother layers of thread pattern 122 together at anchor points and otherintersection points between continuous threads. For example, in a threadpattern 122 including three layers, each defined by a continuous thread,one of the three continuous threads (e.g., the middle continuous thread)may be a polymeric thread that serves to bond all three threadstogether. In some embodiments, one or more of the layers of threadpattern 122 may be defined by a wound continuous thread coated orimpregnated with an adhesive. In some embodiments, the adhesive may beactivated with the application of heat. In some embodiments, theadhesive may be a dissolvable adhesive that, when contacted with asolvent, such as water, fully or partially dissolves to bond continuousthreads. In some embodiments, one or more layers of thread pattern 122may be defined by a wound continuous thread that is a braided or twistedthread including a polymeric and/or adhesive thread braided or twistedwith a non-polymeric or non-adhesive thread. In such embodiments, thebraided or twisted polymeric and/or adhesive thread may serve to bondthread lines 132 at anchor points 134 and/or intersection points 136.

In some embodiments, thread pattern 122 may define at least 10%, atleast 20%, at least 30%, at least 40%, at least 50%, at least 60%, atleast 70%, at least 80%, or at least 90% of a component of upper 120. Insome embodiments, thread pattern 122 may occupy at least 10%, at least20%, at least 30%, at least 40%, at least 50%, at least 60%, at least70%, at least 80%, or at least 90% of the outer surface area of upper120. In some embodiments, thread pattern 122 may be visibly exposed onthe outer surface of upper 120. In some embodiments, no lamination layeror supporting textile layer is disposed over thread pattern 122 on theouter surface of upper 120. In some embodiments, thread pattern 122 maybe devoid of a lamination layer.

Thread pattern 122 may provide targeted characteristics (e.g., strength,support, propulsion, breathability, comfort (stretchability), tackiness,abrasion resistance, texture, haptics, and durability) to areas of upper120. In some embodiments, thread pattern 122, or a portion thereof, mayprovide a first degree of a characteristic in one area of upper 120 anda second degree of that characteristic in a second area of upper 120.

For example, in some embodiments, thread pattern 122, or a portionthereof, may have a first degree of stretchability or strength in alongitudinal direction between forefoot end 102 and heel end 104 ofupper 120 and a second degree of stretchability or strength in atransverse direction between a medial side 106 and a lateral side 108 ofupper 120. In some embodiments, the first degree of stretchability orstrength may be greater than the second degree of stretchability orstrength. In some embodiments, the first degree of stretchability orstrength may be less than the second degree of stretchability orstrength. In some embodiments, the stretchability or strength of threadpattern 122 may be configured to have an angled stretchability orstrength (i.e., a maximum or minimum stretchability or strength in adirection between the longitudinal direction and the transversedirection). In some embodiments, different degrees and/or directions ofstretchability or strength in different sections/areas of upper 120 maybe used to create angled stretchability or strength for upper 120 as awhole.

As another example, thread pattern 122, or a portion thereof, may have afirst degree of breathability or tackiness in heel portion 114 of upper120 and a second degree of breathability or tackiness in forefootportion 110 of upper 120. In some embodiments, the first degree ofbreathability or tackiness may be greater than the second degree ofbreathability or tackiness. In some embodiments, the first degree ofbreathability or tackiness may be less than the second degree ofbreathability or tackiness.

FIG. 2 shows a method 200 of making an upper (e.g., upper 120), and anarticle of footwear (e.g., article of footwear 100) according to someembodiments. In step 210, a plurality of anchor points (e.g., anchorpoints 134) may be defined. The anchor points may be peripheral anchorpoints. In some embodiments, the anchor points may include interioranchor points as discussed herein (see interior anchor points 650 inFIG. 6).

In step 220, one or more continuous threads (e.g., continuous thread130) may be wound (wrapped) around the defined anchor points such thatindividual thread lines (e.g., thread lines 132) of the continuousthread(s) extend between two respective anchor points. Windingcontinuous thread(s) in step 220 forms a desired thread pattern (e.g.,thread pattern 112). During winding step 220, anchor points are definedby fixed or moveable members, such as pins, projections, nubs, or shaftscoupled to a support structure (e.g., pins 1250 coupled to pin assemblyplate 1250). These fixed members serve to support continuous thread(s)during winding step 220. For example, thread(s) may be wound aroundanchor points on a plate, a three-dimensional object (e.g., a last), ora frame as discussed herein. In some embodiments, the plate, object, orframe may be held stationary and a winding device may wind thread(s)around stationary anchor points. In some embodiments, the plate, object,or frame may move relative to a stationary thread source during winding.

The anchor point locations about which one or more continuous threadsare wound (wrapped) in step 220 may be temporary structures that areremoved from a thread pattern defining an upper, or may be present in athread pattern defining an upper. Portions of a thread pattern havingone or more temporary anchor point locations may be cut from, orotherwise removed from, a thread pattern when shaping a thread patterninto an upper. In such embodiments, a thread pattern for a finishedupper will have a fewer number of anchor point locations than the numberof anchor point locations used in winding the thread pattern. Forexample, anchor points in excess thread pattern 642 of on exterior sideof bonding layer 630 in FIG. 6 are temporary anchor point locationsremoved from a thread pattern when forming an upper.

In step 230, the continuous thread(s) are bonded within the threadpattern. In some embodiments, continuous thread(s) may be bonded atpoints of intersection between thread lines via, for example, anadhesive, a bonding layer, thermal (conductive or convective) heat(e.g., in a heat press or oven), IR (infrared) heating, laser heating,microwave heating, steam, a mechanical fastener (e.g., a clip), hook andloop fasters, needle-punching, hydro-entanglement, ultrasonic/vibratoryentanglement, felting, knotting, or by pushing one thread line throughthe other thread line(s). In some embodiments, continuous thread(s) maybe bonded at the anchor points via, for example, an adhesive, a bondinglayer, thermal (conductive or convective) heat (e.g., in a heat press oroven), IR (infrared) heating, laser heating, microwave heating, steam, amechanical fastener (e.g., a clip), hook and loop fasters,needle-punching, hydro-entanglement, ultrasonic/vibratory entanglement,felting, knotting, or by pushing one thread line through the otherthread line(s). In some embodiments, step 230 includes the formation ofa bonding layer for bonding thread lines together.

In some embodiments, method 200 may include multiple winding steps 220and multiple bonding steps 230. For example, a portion of a threadpattern may be wound in a first winding step 220 and then that portionmay be bonded in a first bonding step 230. Then a second portion of athread pattern may be wound in a second winding step 220 and then thatportion may be bonded in a second bonding step 230. In some embodiments,bonding step 230 may include a preliminary bonding step to hold thepattern of a thread pattern until a final bonding step is performed. Forexample, a preliminary bonding step may allow a thread pattern to beremoved from anchor point pins and be finally bonded after removal.

In some embodiments, steps 220 and 230 are performed in the absence of abase layer disposed between the thread pattern and the support structure(e.g., pin assembly plate 1250). As used herein “base layer” means alayer of material employed to facilitate the placement or arrangement ofthreads when winding and/or bonding a thread pattern. A base layer maybe a layer to which threads are bonded, stitched, woven into, printedon, deposited on, or otherwise in contact with during manufacturing of athread pattern. A layer attached to a thread pattern after formation ofthe thread pattern is complete is not considered a base layer.

In some embodiments, a support layer may be attached to a thread patternin step 240. In some embodiments, the support layer attached in step 240may be a fabric layer 172 discussed herein. In some embodiments, thethread pattern may be attached to a sole in step 250 to form an articleof footwear. In some embodiments, continuous thread(s) of the threadpattern may be directly attached to a sole in step 250 via, for example,stitching, an adhesive, a lamination process, or a heat pressingprocess. In some embodiments, the bonding layer of a thread pattern maybe attached to a sole in step 250 via, for example, stitching, anadhesive, a lamination process, or a heat pressing process. Inembodiments including a support layer, the support layer mayadditionally or alternatively be attached to the sole in step 250. Insome embodiments, step 250 may include shaping a thread pattern into theshape of an upper (e.g., by cutting excess portions of a thread patternto for a thread pattern with a perimeter shape for an upper).

In some embodiments, the anchor points in step 210 may be defined bypins coupled to and extending from a supporting structure, such as aplate, platform, or three-dimensional object. In some embodiments, thethree-dimensional object may be a last or other three dimensional objecthaving a volumetric shape corresponding to the shape of a human foot. Inoperation, the pins defining the anchor points are configured to supportthe continuous thread(s) during winding in step 220.

FIG. 3 shows continuous threads 310 and 320 wound around anchor pointpins 304 coupled to a pin assembly plate 300 to define a thread pattern302. Thread pattern 302 in FIG. 3 is a representative exemplary threadpattern. Any thread pattern discussed herein (e.g., thread pattern 122)may be wound around anchor point pins 304 coupled to pin assembly plate300. Anchor point pins 304 extend from an upper surface 308 of pinassembly plate 300 and serve to support continuous threads 310 and 320during winding of thread pattern 302. Anchor point pins 304 may beperipheral anchor point pins 304 arranged in a peripheral areacorresponding to a perimeter portion of an upper. In some embodiments,anchor point pins 304 may include interior anchor point pins. In someembodiments, pin assembly plate 300 may be pin assembly plate 1200discussed in regards to FIGS. 12A-C.

First continuous thread 310 may be wound about anchor point pins 304with thread lines 312 extending between two respective anchor point pins304. In other words, first continuous thread 310 may be wrapped around afirst anchor point pin 304, threaded to a second anchor point pin 304,wrapped around the second anchor point pin 304, threaded to a thirdanchor point pin 304, wrapped around the third anchor point pin 304, andso on.

Similar to first continuous thread 310, second continuous thread 320 maybe wound around anchor point pins 304 with thread lines 322 extendingbetween two respective anchor point pins 304. A continuous threadwrapped or wound around an anchor point pin (or other anchor pointmembers discussed herein) need not be wrapped or wound completely (i.e.,360 degrees) around a perimeter of the pin. A continuous thread wrappedor wound around an anchor point pin may be wrapped or wound around onlya portion of a pin. For example, a continuous thread wrapped or woundaround a pin may be wrapped or wound around 25% (90 degrees) of a pin'sperimeter, 50% (180 degrees) of a pin's perimeter, 75% (270 degrees) ofa pin's perimeter, or 100% (360 degrees) of a pin's perimeter. In someembodiments, a continuous thread may be wrapped or wound around a pin'sperimeter more than once before being threaded to the next pin. Forexample, a continuous thread may be wrapped or wound around a pin'sperimeter one and a half times (540 degrees) or twice (720 degrees)before being threaded to the next pin.

Continuous threads 310 and 320 may be wrapped around any number ofanchor point pins 304 to define thread pattern 302. In some embodiments,continuous thread 310 and/or continuous thread 320 may be wrapped orwound around a single anchor point pin 304 more than once during windingin step 220. For example, during winding in step 220, first continuousthread 310 may be wrapped around a first anchor point pin 304, threadedto and wrapped around a second anchor point pin 304, thread to andwrapped around a third anchor point pin 304, and threaded to and wrappedaround the first anchor point pin 304 again. As another example, duringwinding in step 220, first continuous thread 310 may be wrapped around afirst anchor point pin 304, threaded to and wrapped around a secondanchor point pin 304, and threaded to and wrapped around the firstanchor point pin 304 again. In such embodiments, this creates overlayingthread lines 312.

During winding in step 220, thread lines 312 of first continuous thread310 may overlap each other at intersection points 316. Similarly, threadlines 322 of second continuous thread 320 may overlap each other atintersection points 326. In bonding step 230, thread lines 312 and/or322 may be bonded at intersection points 316 and 326, respectively. Eachanchor point pin 304 may have a thread line communication number forfirst continuous thread 310 and second continuous thread 320 asdiscussed herein.

FIGS. 4A and 4B show continuous thread 410 wrapped around peripheralanchor point pins 404 and interior anchor point pins 406 coupled to athree dimensional object 400 to define a thread pattern 402. Threadpattern 402 in FIGS. 4A-4B is representative exemplary thread pattern.Any thread pattern discussed herein (e.g., thread pattern 122) may bewound around anchor points pins 404/406 coupled to three dimensionalobject 400. Anchor point pins 404 and 406 extend from an exteriorsurface 408 of three dimensional object 400 and serve to supportcontinuous thread(s) during winding of thread pattern 402.

Peripheral anchor point pins 404 may be arranged in a peripheral areacorresponding to a perimeter portion of an upper including threadpattern 402. Interior anchor point pins 406 may be disposed in the areabetween peripheral anchor point pins 404 (i.e., within perimeter portion162 of upper 120, including the quarter panels, vamp portion, and toebox portion of upper 120 including thread pattern 402). Interior anchorpoint pins 406 may be arranged to provide additional points for fixingthread lines in a thread pattern. These additional points may providedesired characteristics to corresponding areas of a thread pattern, andtherefore an upper. Interior anchor points, such as interior anchorpoint pins 406 may be utilized in the formation of any thread patterndiscussed herein.

Similar to first continuous thread 310, continuous thread 410 may bewound around anchor point pins 404 and 406 with thread lines 412extending between two respective anchor point pins 404/406. For example,continuous thread 410 may be wrapped around a first anchor point pin404, threaded to a second anchor point pin 406, wrapped around thesecond anchor point pin 406, threaded to a third anchor point pin 404,wrapped around the third anchor point pin 404, and so on.

Also similar to continuous thread 310, continuous thread 410 may bewrapped around any number of anchor point pins 404/406 to define threadpattern 402. In some embodiments, continuous thread 410 may be wrappedor wound around a single anchor point pin 404/406 more than once duringwinding in step 220. Further, during winding in step 220, thread lines412 of continuous thread 410 may overlap each other at intersectionpoints 416. And each anchor point pin 404/406 may have a thread linecommunication number for continuous thread 410. In bonding step 230,thread lines 412 may be bonded at anchor points 404/406 and/orintersection points 416.

In some embodiments, padding may be incorporated into a thread patternfor providing cushioning, support, and/or protection to areas of anupper. In some embodiments, padding may be incorporated into a threadpattern prior to bonding in step 230. Padding may be incorporated intoone or more areas of an upper (e.g., upper 120), such as but not limitedto, the throat area 150 of upper 120, collar 156 of upper 120, heelcounter 158 of upper 120, biteline 160 of upper 120, quarter panels ofupper 120, vamp portion of upper 120, and toe box portion of upper 120.

FIG. 5 shows an exemplary thread pattern 500 including padding elements530 according to some embodiments. Thread pattern 500 in FIG. 5 isrepresentative exemplary thread pattern. Any thread pattern discussedherein (e.g., thread pattern 122) may include padding elements 530.Thread pattern 500 may be made using method 200 and may be used toconstruct an upper (e.g., upper 120) as discussed herein.

Similar to other thread patterns discussed herein, thread pattern 500includes first and second continuous threads 510 and 520 wound aroundanchor points 514 with thread lines 512 and 522 extending between tworespective anchor points 514. Thread lines 512 of first continuousthread 510 may overlap each other at intersection points 516. Similarly,thread lines 522 of second continuous thread 520 may overlap each otherat intersection points 526.

In some embodiments, padding elements 530 may be disposed within threadpattern 500 vertically between thread lines 512 of first continuousthread 510 and/or thread lines 522 of second continuous thread 520. Insuch embodiments, padding elements 530 may be suspended between threadlines 512/522 of thread pattern 500. For example, in some embodiments,some thread lines 512 may be disposed above (i.e., on the outer side of)padding elements 530 and some thread lines 512 may be disposed below(i.e., on the inner side of) padding elements 530 to support paddingelements within thread pattern 500. As another example, in someembodiments, some thread lines 522 may be disposed above paddingelements 530 and some thread lines 522 may be disposed below paddingelements 530 to support padding elements within thread pattern 500. Asanother example, in some embodiments, some thread lines 512 may bedisposed above padding elements 530 and some thread lines 522 may bedisposed below padding elements 530. Padding elements 530 may becomposed of, for example, neoprene, ePEBA, eTPU, EVA, TPU, or a foam,such as polyethylene foam, polyurethane foam, or a urethane foam.Padding elements 530 may be placed within thread pattern 500 duringwinding step 220 so as to suspend padding elements 530 within threadpattern 500.

After winding one or more continuous threads in step 220 to form athread pattern, thread lines of a thread pattern may be bonded tomechanically set the thread pattern. Thread lines may be bonded at oneor more anchor points, one or more intersection points, and/or in anarea corresponding to bonding layer (e.g., perimeter portion 162 ofupper 120). FIGS. 6 and 7 show a thread pattern 600 bonded at selectanchor points 614, intersection points 616/626/652 between thread lines,and a bonding layer 630 according to some embodiments. Thread pattern600 in FIG. 6 is representative exemplary thread pattern. Any threadpattern discussed herein (e.g., thread pattern 122) may include abonding layer like bonding layer 630.

Thread pattern 600 may be made using method 200 and may be used toconstruct an upper (e.g., upper 120) as discussed herein. Similar toother thread patterns discussed herein, thread pattern 600 includesfirst and second continuous threads 610 and 620 wound around anchorpoints 614/650 with thread lines 612 and 622 extending between tworespective anchor points 614. Thread lines 612 of first continuousthread 610 may overlap each other at intersection points 616. Similarly,thread lines 622 of second continuous thread 620 may overlap each otherat intersection points 626. Anchor points 614 are peripheral anchorpoints and anchor points 650 are interior anchor points disposed betweenperipheral anchor points 614.

Bonding layer 630 is configured to bond thread line groups 618 of threadlines 612 and/or thread line groups 628 of thread lines 622 atrespective areas 632 of bonding layer 630. Thread line groups 618/628bonded at respective areas 632 may extend radially from areas 632. Insome embodiments, bonding layer 630 may coincide with one or more anchorpoints 614. In such embodiments, groups of thread lines 612 and/or 622may be bonded at areas 632 of bonding layer 630 including anchor points614. In such embodiments, groups of thread lines 612 and/or 622 may bebonded at areas 632 of bonding layer 630 including anchor points 650. Insome embodiments, bonding layer 630 may bond groups of thread lines 618and/or 628 at respective areas 632 that do not coincide with anchorpoints 614 and/or anchor points 650. FIG. 20C illustrates a bondinglayer 630 that does not coincide with any anchor points according tosome embodiments.

In addition to bonding layer 630, thread lines 612 and 622 may be bondedtogether at intersection points 616 and 626, respectively, orintersection points 652 between thread lines 612 and 626 via forexample, an adhesive, a bonding layer, thermal (conductive orconvective) heat (e.g., in a heat press or oven), IR (infrared) heating,laser heating, microwave heating, steam, a mechanical fastener (e.g., aclip), hook and loop fasters, needle-punching, hydro-entanglement,ultrasonic/vibratory entanglement, felting, knotting, or by pushing onethread line through the other thread line(s). In some embodimentsincluding a continuous thread 610 and/or 620 composed of a polymericmaterial, the polymeric material of continuous thread 610 and/or 620 maydirectly bond thread lines 612 and/or 622 at intersection points. Insuch embodiments, the polymeric material of continuous thread 610 and/or620 serves to bond thread lines 612/622 at intersection points.

FIG. 7 shows thread pattern 600 bonded to a sole 780 and defining anupper 720 for an article of footwear 700 according to some embodiments.After bonding thread pattern 600 in step 230, and optionally attaching asupport layer to thread pattern in step 240, excess thread pattern 642on exterior side of bonding layer 630 may be removed (e.g., via acutting process) leaving only interior portion 640 of thread pattern 600and bonding layer 630. Then, thread pattern 600 (and the optionalsupport layer) may be coupled to a sole in step 240.

In some embodiments, a thread model may be used to create a threadpattern for winding step 220. A thread model may be created manually orautomatically based on desired characteristics for a footwear component(e.g., an upper) or may be computer generated based on desiredcharacteristics for a footwear component. Desired characteristicsinclude both aesthetic and functional characteristics. A thread modelmay define one or more of: (a) the location of anchor points (peripheraland/or interior) for a thread pattern, (b) the number of anchor points(peripheral and/or interior) for a thread pattern, (c) the number ofcontinuous threads for a thread pattern, (d) the thread linecommunication number for each continuous thread at each anchor point ina thread pattern, (e) which respective anchor points are connected by athread line (and thus directional orientation of individual threadlines) within a thread pattern, (f) the number of times which respectiveanchor points are connected by thread lines in a thread pattern, (g) thenumber of intersection points between thread lines, (h) the tension atwhich a continuous thread is wound in a thread pattern, and (i) thematerial(s) of continuous threads within a thread pattern. In someembodiments, a thread model may be used as a template for hand windingcontinuous thread(s) into a thread pattern. In some embodiments, athread model may be sent to an automated machine, such as a CNC(Computer Numerical Control) machine, and converted into machinereadable instructions for winding a thread pattern.

In some embodiments, biometric data may be used to generate a threadmodel for a thread pattern. In such embodiments, winding step 220 mayinclude collecting a biometric data profile for an individual (e.g.,individual 2300 shown in FIG. 22), or group of individuals. In someembodiments, a biometric data profile may be collected by scanning afoot, by measuring a foot. In some embodiments, a biometric data profilemay include foot geometry data, foot volume data, and/or dynamic changesin foot characteristics during an activity.

In some embodiments, a biometric data profile may be collected using aphysiological and personal characteristic collection and analysissystem, such as a Run Genie® system. In some embodiments, the biometricdata profile may be collected using the data collection and analysissystem described in U.S. patent application Ser. No. 14/579,226, filedon Dec. 22, 2014, and published as US 2016/0180440, which is herebyincorporated by reference in its entirety by reference thereto. In someembodiments, a biometric data profile may include data related to anindividual's gait collected using a Vicon® Motion Capture System withforce plates. In some embodiments, a biometric data profile may includea digital last created according to the processes described U.S. patentapplication Ser. No. 15/478,902, filed on Apr. 4, 2017, and published asUS 2017/0280828, which is hereby incorporated by reference in itsentirety by reference thereto. In some embodiments, biometric data mayinclude strain data for an article of footwear collected using anARAIVIIS system from GOM mbH.

FIGS. 24A and 24B illustrate an exemplary strain data map 2400 and athread pattern 2450 wound around anchor points 2452 based on stain datamap 2400. Strain data map 2400 may be captured during a test method thatevaluates strain imparted on areas of an article of footwear worn duringthe test, using for example, an ARAMIS system from GOM mbH. The datacaptured in the test method may be translated into a two-dimensionalpattern in the shape of an upper as shown in FIG. 24A. Darker areas ofmap 2400 represent low strain values and lighter areas of map 2400represent high strain values. Accordingly, areas of thread pattern 2450corresponding to darker areas of map 2400 may have a relatively smallnumber of thread lines while areas of thread pattern 2450 correspondingto lighter areas of map 2400 may have a relatively larger number ofthread lines. The larger number of thread lines may provide increasedstrength in areas of high strain, which may indicate areas in which thetested individual needs more support from his or her article offootwear. Alternative or additional characteristics of thread pattern2450, such as anchor points, the number and configuration of continuousthreads wound around the anchor points, and the material of thecontinuous thread(s) may also be selected to provide increased strengthin areas of high strain. Alternatively, characteristics of threadpattern 2450 may be selected to less strength in areas of high strain.

The physiological characteristics collected in step 220 may include, butare not limited to, gait characteristics, such as foot strike type (e.g.heel, midfoot, forefoot, etc.), rate of pronation or supination, anddegree of pronation and/or supination. In some embodiments, step 220 mayinclude receiving personal information about the individual before orafter receiving physiological characteristics data about the individual.Personal information may include information such as the individual'sname, prior injury information, height, weight, gender, shoe size, anathletic goal, intended athletic activity, intended athletic environmentor terrain, intended athletic activity duration, intended athleticactivity frequency, intended athletic activity distance, quantitative orqualitative preferences about athletic equipment or footwear (such aslevel of cushion, preference of weight, materials and the like), andcurrent athletic footwear. Intended athletic activities include, but arenot limited to, basketball, running, sprinting, training, football,soccer, rugby, and baseball.

In some embodiments, step 220 may include receiving biometric data via alocal wired or wireless connection. In some embodiments step 220 mayinclude monitoring individual 2300 in real time during an athleticactivity, such as jogging.

Physiological characteristics may be collected using one or more sensormodules 2302. A sensor module 2302 may include one or more sensors, andmay be physically coupled to an object (e.g., article of footwear 2304)during an everyday or athletic activity conducted by individual 2300. Asensor module 2302 may be used to monitor changes in the spatialorientation of an individual's body or a piece of the individual'sathletic equipment or article of footwear in some embodiments. Sensormodule 2302 may be used in combination with predetermined correlationdata stored in a data structure to determine a correlation between bodyor equipment or article of footwear movement data and a characteristicsuch as a gait characteristic in some embodiments.

In some embodiments, a sensor module 2302 is placed and/or built intoarticle of footwear 2304 to measure, for example, a runner's runningform and gait cycle (e.g., sensor is placed on, removably attached to,or built into the heel, midsole, or toe of article of footwear 2304).Additional sensors/motion monitors can also be placed on the runner'sknee and hip, for example, to obtain more information about the runner'srunning form.

Sensor module 2302 may include a plurality of sensors, including but notlimited to, one or more motion sensors, such as acceleration sensors andmagnetic field sensors, or angular momentum sensors. In someembodiments, sensor module 2302 may include one or more temperaturesensors, a heart rate monitoring device, a pedometer, and/or anaccelerometer-based monitoring device. Sensors of sensor module 2302 maybe capable of measuring a variety of athletic performance parameters.The term “performance parameters” may include physical parameters and/orphysiological parameters associated with the individual's 2300 athleticactivity. Physical parameters measured may include, but are not limitedto, time, distance, speed, pace, pedal count, wheel rotation count,rotation generally, stride count, stride length, airtime, stride rate,altitude, temperature, strain, impact force, jump force, forcegenerally, and jump height. Physiological parameters measured mayinclude, but are not limited to, heart rate, respiration rate, bloodoxygen level, blood lactate level, blood flow, hydration level, caloriesburned, or body temperature.

An acceleration sensor may be adapted to measure the acceleration of thesensor module 2302. Accordingly, when the sensor module 2302 isphysically coupled to an object (such as an individual's 2300 body,article of footwear 2304, or other piece of athletic equipment), theacceleration sensor may be capable of measuring the acceleration of theobject, including the acceleration due to the earth's gravitationalfield. In some embodiments, an acceleration sensor may include atri-axial accelerometer that is capable of measuring acceleration inthree orthogonal directions. In some embodiments one, two, three, ormore separate accelerometers may be used.

A magnetic field sensor may be adapted to measure the strength anddirection of magnetic fields in the vicinity of sensor module 2302.Accordingly, when sensor module 2302 is physically coupled to an object(such as an individual's 2300 body, article of footwear 2304, or other apiece of athletic equipment), a magnetic field sensor may be capable ofmeasuring the strength and direction of magnetic fields in the vicinityof the object, including the earth's magnetic field. In someembodiments, a magnetic field sensor may be a vector magnetometer. Insome embodiments, a magnetic field sensor may be a tri-axialmagnetometer that is capable of measuring the magnitude and direction ofa resultant magnetic vector for the total local magnetic field in threedimensions. In some embodiments one, two, three, or more separatemagnetometers may be used.

In some embodiments, an acceleration sensor and a magnetic field sensormay be contained within a single accelerometer-magnetometer modulebearing model number LSM303DLHC made by STMicroelectronics of Geneva,Switzerland.

An angular momentum sensor, which may be, for example, a gyroscope, maybe adapted to measure the angular momentum or orientation of sensormodule 2302. Accordingly, when the sensor module 2302 is physicallycoupled to an object (such as an individual's 2300 body, article offootwear 2304, or other athletic equipment), the angular momentum sensormay be capable of measuring the angular momentum or orientation of theobject. In some embodiments, an angular momentum sensor may be atri-axial gyroscope that is capable of measuring angular rotation aboutthree orthogonal axes. In some embodiments one, two, three, or moreseparate gyroscopes may be used. In some embodiments, angular momentumsensor may be used to calibrate measurements made by one or more of anacceleration sensor and a magnetic field sensor.

A heart rate sensor may be adapted to measure individual's 2300 heartrate. A heart rate sensor may be placed in contact with the individual's2300 skin, such as the skin of the individual's chest, and secured witha strap. A heart rate sensor may be capable of reading the electricalactivity of the individual's 2300 heart.

A temperature sensor may be, for example, a thermometer, a thermistor,or a thermocouple that measures changes in the temperature. In someembodiments, a temperature sensor may primarily be used for calibrationother sensors, such as, for example, an acceleration sensor and amagnetic field sensor.

In some embodiments, sensor module 2302 may include a position receiver,such as an electronic satellite position receiver that is capable ofdetermining its location (i.e., longitude, latitude, and altitude) usingtime signals transmitted along a line-of-sight by radio from satelliteposition system satellites. Known satellite position systems include theGPS system, the Galileo system, the BeiDou system, and the GLONASSsystem. In some embodiments, a position receiver may be an antenna thatis capable of communicating with local or remote base stations or radiotransmission transceivers such that the location of sensor module 2302may be determined using radio signal triangulation or other similarprinciples. In some embodiments, position receiver data may allow sensormodule 2302 to detect information that may be used to measure and/orcalculate position waypoints, time, location, distance traveled, speed,pace, or altitude.

Data collected by sensor module 2302 may classify individuals based ontheir running style, utilizing data analysis such as ananterior-posterior plot angle vs. time; medial-lateral plot angle vs.time; and the like. Calculations of these characteristics may be used togroup individuals into different categories (groups), such as a heelstriker, a midfoot striker, a forefoot striker, a pronator, supinator, aneutral individual, or some combination of characteristics. In someembodiments, gait analysis may utilize personal information ofindividual 2300, such a gender, shoe size, height, weight, runninghabits, and prior injuries.

In some embodiments, a regression analysis can be used to determine gaitcharacteristics such as foot strike type, rate of pronation, degree ofpronation, and the like based on acceleration data obtained from sensormodule 2302. In some embodiments, the regression analysis can be used todetermine gait characteristics such as foot strike type, rate ofpronation, degree of pronation, and the like based on other data such asmagnetometer data, angular momentum sensor data, or multiple types ofdata. In some embodiments, the analysis can include other user-inputinformation such as prior injury information, an athletic goal, intendedathletic environment or terrain, intended athletic duration, and currentathletic footwear.

Athletic goals may be, for example, training for a race, to stayhealthy, to lose weight, and training for sports. Other examples ofathletic goals may include training for a race, or other sporting event,improving individual fitness, simply enjoy running, or the like.Frequency intervals may include for example about 1 to 2 times per week,about 3 to 4 times per week, about 5 to 7 times per week, or theindividual doesn't know. Length intervals may include for example aboutless than about 5 miles per week, about 5 to 10 miles per week, about 10to 20 miles per week, greater than about 20 miles per week, or theindividual doesn't know. Examples of intended athletic terrainenvironments may include roads, track, treadmill, trail, gym, orparticular athletic fields designed for a specific sport. Examples ofathletic equipment preferences may include for example more cushioning,less weight, better fit, strength, durability, intended athleticactivity range, balance, weight balance, more color choices, and thelike.

In some embodiments, collecting a biometric data profile in step 220 mayinclude obtaining previously collected and stored data for anindividual. In some embodiments, collecting biometric data may includeobtaining a standard biometric data profile for a group of individuals.For example, a standard profile for individuals having a certain shoesize, weight, height, arch shape, stability characteristic, and/ortouchdown characteristic may be retrieved in step 220.

Modeling software such as CAD drawings, Grasshopper™, and Rhino® may beutilized to generate thread models and convert thread models into threadpatterns based on input data. Input data may include templates for aparticular footwear type, anchor point location and arrangement, timingfor anchor point pin retraction(s) and/or extension(s), desired threadline orientation relative to strain direction, thread line densityand/or thread materials in areas of high and/or low stain magnitude,thread line tension values, number and location of continuous threads ina thread pattern, and continuous thread material characteristics (e.g.,tackiness, color, or tensile strength). As an example, the location ofanchor point pins 304 in FIG. 3 may be an input template for anchorpoints. The modeling software may correlate collected data (e.g., strainand biometric data) to the given inputs in order to wind a desiredthread pattern. Exemplary footwear type templates include, a basketballshoe template, a soccer cleat template, a tennis shoe template, afootball cleat template, and a baseball cleat template.

FIGS. 8A-8D show four exemplary thread models 800, 820, 840, and 860according to some embodiments. Each thread model 800/820/840/860 isbased on strain data for an upper of an article of footwear collectedusing, for example, an ARAMIS system from GOM mbH. The different models800, 820, 840, and 860 impart desired characteristics to a threadpattern, which may be tailored to the desires and/or needs of anindividual, or group of individuals. The density and orientation oflines in thread models 800/820/840/860 indicate the characteristics ofthread lines (e.g., number, material, and orientation) in a threadpattern based on the respective model. In some embodiments, two or morethread models may be included in a thread pattern for an article offootwear. In other words, a thread pattern may include thread linesbased on two or more thread models to provide characteristics of the twoor more models to an article of footwear.

FIGS. 8A and 8B show thread models 800 and 820 having a relatively highdensity of lines in areas of high stain magnitude. Thread model 800 hasa relatively high density of lines in areas extending between areas ofhigh strain magnitude and oriented in the direction generally parallelto the direction of the strain in the high magnitude areas (i.e., lessthan 45 degrees different from the direction of the strain in the highmagnitude areas). Thread model 820 has a relatively high density oflines in areas of high strain magnitude and oriented in directionsgenerally perpendicular to and generally parallel to the direction ofthe strain in the high magnitude areas (i.e., 45 degrees to 90 degreesand less than 45 different from the direction of the strain in the highmagnitude areas). As illustrated in FIGS. 8A and 8B, the relatively highdensity of lines results in a relatively large number of intersectionpoints between the lines.

When incorporated into an upper, thread patterns based on thread models800 and 820 may provide a wearer with a relatively large amount ofstrength and propulsion in areas of high strain magnitude. Suchcharacteristics may be desirable/needed by, for example, an athleteparticipating in a high strain activity, such as a sport (e.g.,basketball or football). Such characteristics may maximize the energytransfer between the individual's foot and a surface (i.e., reducingenergy lost via and/or absorbed by an article of footwear) and mayprovide a durable article of footwear for use in such activities. Threadmodel 800 may provide a more lightweight and breathable thread patternfor an upper compared to thread model 820 due to a relatively smallnumber of thread lines.

The strength and/or propulsion of a thread pattern based on threadmodels 800 and 820 may be imparted in areas of high strain magnitude by:(a) winding a relatively large number of thread lines oriented in thedirection of lines in the models between anchor points in these areas,(b) providing a relatively large number of anchor points in the areas,and/or (c) selecting a relatively stiff material for thread lines in theareas. (a) may be achieved by winding more thread lines for a singlecontinuous thread, winding additional continuous threads, and/orincreasing the thread line communication number of continuous thread(s)at anchor points in the areas.

FIGS. 8C and 8D show thread models 840 and 860 having a relatively lowdensity of lines in areas of high stain magnitude. Thread model 840,when compared to models 800 and 820, has a relatively low density oflines in areas of high strain magnitude and a larger majority of thethread lines oriented in the direction generally parallel to thedirection of the strain in the high magnitude areas (i.e., less than 45degrees different from the direction of the strain in the high magnitudeareas). Thread model 860, when compared to models 800, 820, and 840, hasa relatively low density of lines in areas of high strain magnitude andthe lines that are present are generally perpendicular to the directionof the strain in the high magnitude areas (i.e., 45 degrees to 90degrees different from the direction of the strain in the high magnitudeareas). As illustrated in FIGS. 8C and 8D, when compared to FIGS. 8A and8D, the relatively low density of lines results in a relatively lownumber of intersection points between the lines.

When incorporated into an upper, thread patterns based on thread models840 and 860 provide a wearer with a relatively large amount ofstretchability and/or breathability in areas of high strain. Suchcharacteristics may be desirable/needed by, for example, an individualparticipating in a leisurely activity, such as walking. The flexibilityand/or breathability of a thread pattern based on thread models 840 and860 may be imparted in areas of high strain magnitude by: (a) winding arelatively small number of thread lines oriented in the direction oflines in the models between anchor points in these areas, (b) providinga relatively small number of anchor points in the areas, and/or (c)selecting a relatively flexible material for thread lines in the areas.(a) may be achieved by winding less thread lines for a single continuousthread, winding less continuous threads, or/or decreasing the threadline communication number of continuous thread(s) at anchor points inthe areas. Thread model 840 may provide a thread pattern having morestrength and propulsion in high strain areas compared to thread model860, whereas thread model 860 may provide a thread pattern having morestrength and stability in midfoot and heel portions for an upper. Insome embodiments, thread patterns based on thread models 840 and 860 mayprovide a wearer with a relatively large amount of support and/orstiffness in areas of low strain by, for example, threading continuousthread(s) with a high stiffness in areas of low strain. In someembodiments, thread patterns based on thread models 840 and 860 mayprovide a wearer with a relatively large amount of support and/orstiffness in areas of high strain by, for example, threading continuousthread(s) with a high stiffness in areas of high strain.

FIGS. 9A and 9B illustrate how different thread types (e.g., threadsmade of different materials) can be utilized to create thread patterns900 and 950 having desired characteristics. Thread patterns 900 and 950both include a first continuous thread 910, a second continuous thread920, and a third continuous thread 930 wound around the same set ofanchor points, including peripheral anchor points 904 and interioranchor points 906. First continuous thread 910 has a high tensilestiffness, second continuous thread 920 has a medium tensile stiffness,and third continuous thread 930 has a low tensile stiffness.

In thread pattern 900, first and second continuous threads 910 and 920,and particularly first continuous thread 910 are wound significantlyaround anchor points 904/906 associated the quarter panels and bitelineareas of an upper. As such, thread pattern 900 provides a large amountof strength and propulsion for an upper in these areas. Conversely, inthread pattern 950, third and second continuous threads 930 and 920, andparticularly third continuous thread 930, are wound significantly aroundanchor points 904/906 associated the quarter panels and biteline areasof an upper. As such, thread pattern 950 provides a large amount ofstretchability for an upper in these areas.

In some embodiments, a thread pattern for an upper wound and bonded insteps 220 and 230 may extend underneath a wearer's foot when worn. Inother words, the thread pattern for the upper may wrap around at least aportion of the bottom (i.e., the sole) of a wearer's foot when worn.FIG. 10 illustrates an upper 1000 including a thread pattern 1002 thatwarps around the sole of a wearer's foot according to some embodiments.

Upper 1000 includes an upper section 1040 configured to wrap around thesides, the top, and the heel of a wearer's foot and a sole section 1042configured to wrap around the sole of a wearer's foot. Thread pattern1002 may define at least a portion of upper section 1040 and solesection 1042.

In some embodiments, similar to other thread patterns discussed herein,thread pattern 1002 includes a first continuous thread 1010 and a secondcontinuous thread 1020 wound around anchor points 1014. First continuousthread 1010 includes thread lines 1012 extending between respectiveanchor points 1014 and overlapping at intersection points 1016. Andsecond continuous thread 1020 includes thread lines 1022 extendingbetween respective anchor points 1014 and overlapping at intersectionpoints 1026. In some embodiments, one or more anchor points 1014 may bedisposed in sole portion 1042.

In some embodiments, upper 1000 may include a bonding layer at perimeterportion 1030 of upper configured to bond thread lines 1012/1022 togetherin perimeter portion 1030. Perimeter portion 1030 may be the same as orsimilar to perimeter portion 162 discussed herein in regards to upper120. In some embodiments, upper 1000 may include a fabric layer 1050disposed on the outer surface and/or the inner surface of thread pattern1002. Fabric layer 1050 may be the same as or similar to fabric layer172 discussed herein with regards to upper 120.

In some embodiments, a sole for an article of footwear may include oneor more continuous threads wound around anchor points to form a threadpattern. Thread patterns for a sole may provide desired characteristicsto the a sole in the same fashion as thread patterns for uppersdiscussed herein. In particular, thread patterns for a sole may providereinforcement (i.e., additional strength) for portions of the sole. Thestrength provided by a thread pattern may decrease the weight of a solewithout sacrificing strength. FIG. 11 illustrates a sole 1100 includinga continuous thread 1130 wound around anchor points 1114 to form athread pattern 1120.

Sole 1100 includes a forefoot end 1102, a heel end 1104, a medial side1106, a lateral side 1108, a top surface 1110, and a bottom (groundcontacting) surface 1112 opposite top surface 1110. Similar to otherthread patterns discussed herein, thread pattern 1120 includes acontinuous thread 1130 wound around anchor points 1114. And continuousthread 1130 includes thread lines 1132 extending between respectiveanchor points 1114 and overlapping at intersection points 1136. In someembodiments, one or more anchor points 1114 may be studs or cleatsextending from bottom surface 1112 of sole 1100. In such embodiments,the location of one or more anchor points 1114 corresponds to thelocation of a cleat extending from bottom surface 1112 of sole 1100.

In some embodiments, continuous thread 1130 may be wound around apre-formed sole 1100 having studs or cleats extending from bottomsurface 1112 of sole 1100. In some embodiments, continuous thread 1130may be wrapped around a pre-formed sole 1100. In other words, one ormore thread lines 1132 of continuous thread 1130 may be wound from ananchor point 1114, across bottom surface 1112, around medial side 1106(or lateral side 1108), across top surface 1110, around lateral side1108 (or medial side 1106), back to bottom surface 1112, around anotheranchor point 1114, and so on. In some embodiments, one or more threadlines 1132 may be wound around sole 1100 more than once before windingaround another anchor point 1114. In some embodiments, sole 1100 mayinclude an outsole coupled to bottom surface 1112. In such embodiments,the outsole may be disposed over thread pattern 1120.

After winding around anchor points 1114 and/or pre-formed sole 1100,continuous thread 1130 may be bonded to bottom surface 1112, top surface1110, medial side 1106, and/or lateral side 1108 of sole 1100.Continuous thread 1130 may be bonded to surfaces and sides of sole 1100via, for example, pressure and heat (e.g., in a heat press or heatedmold), an adhesive, or a lamination layer. In some embodiments, apolymeric material of continuous thread 1130 may be directly bonded tosurfaces and sides of sole 1100 via the application of pressure andheat.

In some embodiments, thread pattern 1120 may include more than onecontinuous thread, such as second and/or third continuous threads 1140and 1150. Similar to continuous thread 1130, second and third continuousthreads 1140 and 1150 may be wound around anchor points 1114 and/or sole1100. In some embodiments, continuous threads 1130 and/or 1140 may be ahigh tensile polymeric thread and third continuous thread 1150 may be acarbon fiber tow. In some embodiments, thread pattern 1120 may includemore than three continuous threads. In some embodiments, one or morecontinuous threads of thread pattern 1120 may define a portion of athread pattern for an upper (e.g., thread pattern 122). In suchembodiments, one or more continuous threads may be wound around anchorpoints of a sole (e.g., anchor points 1114) and anchor points of anupper (e.g., anchor points 134).

In some embodiments, continuous thread(s) 1130/1140 may be wound aroundprojections in a mold cavity and a sole material may be molded aroundthe projections in the mold cavity to bond continuous threads 1130/1140to sole 1100. FIG. 21 illustrates a mold 2100 for molding sole 1100according to some embodiments.

FIGS. 12A-12C illustrate a pin assembly plate 1200 for supporting pins1250 during winding step 220 and bonding step 230 of method 200. Pinassembly plate 1200 includes a top plate 1210, a pin plate 1220, and abottom plate 1230. Top plate 1210 includes a plurality of pin holes 1214extending through top plate 1210 from a top surface 1212 to a bottomsurface 1216 of top plate 1210. In some embodiments, pin holes 1214 maybe arranged in an ordered grid of columns and rows of pins holes 1214with each pin hole 1214 equally spaced from its immediately adjacentneighbors in the column and rows.

Pin plate 1220 is moveably coupled to posts 1222, and in operation,moves vertically up and down between top plate 1210 and bottom plate1230. In some embodiments, posts 1222 may be spring loaded posts. Pinplate 1220 supports pins 1250 extending through pin holes 1214 and movesthem vertically within pin holes 1214. In some embodiments, pins 1250may be removably coupled to pin plate 1220 (e.g., via thread couplingsor luer-lock couplings.) In such embodiments, pin plate 1220 includescoupling holes disposed below individual pin holes 1214. Bottom plate1230 is a supporting plate rigidly coupled to top plate 1210 and posts1222.

The operation of pin assembly plate 1200 is illustrated in FIGS.12A-12C. In FIGS. 12A and 12B, with pin plate 1220 in an upper position,pins 1250 extend from top surface 1212 of top plate 1210. Pins 1250define anchor points for a thread pattern, and the location and numberof pins may be selected to produce a desired thread pattern. Forexample, pins 1250 may be arranged in the same arrangement as pins 304in FIG. 3. In some embodiments, pins 1250 may include pin heads 1252,which may have a diameter larger than the diameter of pin holes 1214. Inthe position shown in FIG. 12A, more or more continuous threads may bewound around pins 1250 to produce a desired thread pattern.

Once a desired thread pattern is wound, pin plate 1220 is moved to alower position away from bottom surface 1216 of top plate 1210 asillustrated in FIG. 12C. In some embodiments, pin plate 1220 may bepushed downward by pushing on pins 1250. For example, a plate may pushdown on pins 1250, thereby forcing pins 1250 down through pin holes1214. In some embodiments, the plate may push pins 1250 down through pinholes 1214 and pin heads 1252 may pull the continuous thread(s) woundaround pins 1250 downward toward top surface 1212 of top plate 1210. Insome embodiments, the plate may be a heated plate that bonds continuousthread(s) wound around pins 1250 when the continuous thread(s) is/aresandwiched between the heated plate and top surface 1212 of top plate1210. In some embodiments, pins 1250 may be composed of a meltablematerial (e.g., a thermoplastic material) that bonds continuousthread(s) at pins 1250 when heated. In some embodiments, a bonding layer(e.g., bonding layers as described herein) may be applied after theheated plate is removed.

In some embodiments, the plate may be a non-heated plate. In suchembodiments, pin heads 1252 may pull the continuous thread(s) woundaround pins 1250 downward toward top surface 1212 of top plate 1210 asthe plate pushes on them. In such embodiments, a bonding layer (e.g.,bonding layers as described herein) may be applied to bond continuousthread(s) wound around pins 1250.

In embodiments with pins 1250 coupled to pin plate 1220, pin plate 1220,or individual pins 1250, may be pulled downward so that pin heads 1252pull the continuous thread(s) wound around pins 1250 downward toward topsurface 1212 of top plate 1210. In such embodiments, a bonding layer(e.g., bonding layers as described herein) may be applied to bondcontinuous thread(s) wound around pins 1250. Pin plate 1220 orindividual pins 1250 may be pulled downward with a pneumatic orelectromagnetic device, for example. In some embodiments, select pins1250 may be retracted at specific times during winding step 220 tocreate a desired thread pattern. Retracting and/or extending pins 1250at desired times during winding step 220 may be used to tailorcharacteristics of a thread pattern, such as, strength, support,propulsion, breathability, comfort (stretchability), tackiness, abrasionresistance, texture, haptics, and durability.

After bonding the continuous thread(s) of the thread pattern, the threadpattern may be removed from pins 1250 and pin plate 1220 may repositionpins 1250 as show in FIGS. 12A and 12B for winding another threadpattern. In some embodiments, the portion of a thread pattern disposedwithin pins 1250 may be cut from pins 1250 and excess portions of thethread patterns around pins 1250 may be discarded.

In some embodiments, a thread pattern may be wound around anchor points(e.g., pins 1250) manually. In some embodiments, a thread pattern may bewound around anchor points (e.g., pins 1250) using an automated,computer-assisted process. FIG. 13 illustrates a CNC machine 1300including a robotic arm 1305 for winding a thread pattern 1320 includingthread lines 1322 around pins 1250 on pin assembly plate 1200. Roboticarm 1305 may include a thread spool 1310 for threading and windingthread lines 1322 of thread pattern 1320 around pins 1250. In someembodiments, CNC machine 1300 may include a thread tensioner 1312configured to apply a desired tension to thread(s) that are wound aroundpins 1250. CNC machine 1300 may include a controller 1315 configured towind a desired thread pattern 1320 around pins 1250 using a thread modeland input data. In some embodiments, controller 1315 may controltensioner 1312 to wind thread(s) at desired tensions. Controller 1315may include components of computer system 2600 discussed herein.

In some embodiments, tensioner 1312 may be a mechanical tensioningdevice with digitally controlled impedance that is used to dynamicallycontrol how tight a thread is fed through a winding machine (e.g., CNCmachine 1300). The thread is run through tensioner 1312 before it exitsthread spool 1310, thereby giving an exact tension as it is fed out. Thetension value for thread can be changed dynamically by adjusting thevoltage in tensioner 1312. In some embodiments, tensioner 1312 may be amanually adjustable tensioner. In some embodiments, tensioner 1312 mayinclude a spring configured to adjust the amount of tension applied tothread(s). The spring may be manually controlled or digitallycontrolled.

Adjusting the tension as the thread is wound can provide a number ofbenefits. With elastic threads, tensioning the threads places a preloadon them, allowing them to act as if they have a different stiffness in athread pattern. By dynamically adjusting the tension, one thread canbehave with a range of stiffness, which allows for customized zones ofstiffness and compliance without the need for changing thread material.This change in stiffness between different zones may be large or small.For example, high stiffness can be provided in areas where hightensioned threads are bonded together and low stiffness can be providedin areas where stretch is preferred. In some embodiments, adjustingthread tension within a thread pattern may facilitate customization ofan article of footwear for an individual, or group of individuals, byproviding desired characteristics to different areas on the footwear.Moreover, tensioning may be used to customize the fit of an article offootwear. For example, when a wound thread pattern is removed from pins1250, the thread pattern may contract to an un-stretched shape, whichrelieves any tension in thread lines that is not fixed by bonding. Thismay facilitate a customized fit for an individual, or group ofindividuals, because the un-stretched shape may better conform with theshape of a wearer's foot. In some embodiments, tensioning andun-stretched shapes may be designed based on biometric data, such asfoot volume data.

In some embodiments, winding step 220 may include winding a threadpattern on a frame. FIGS. 14A and 14B show a frame 1400 for winding athread pattern according to some embodiments. Frame 1400 includes frontside 1401, a rear side 1403, an interior perimeter wall 1402, and anexterior perimeter wall 1404. Interior perimeter wall 1402 of frame 1400defines a hollow opening 1408. Exterior perimeter wall 1404 includes aplurality of projections 1406 extending laterally from exteriorperimeter wall 1404. Projections 1406 may be integrally formed withframe 1400 or may be removably coupled to frame 1400. Projections 1406may be pins, knobs, or studs.

In operation, a thread pattern 1410 may be wound around projections1406. When winding thread pattern 1410, one or more continuous threads(e.g., continuous threads 1420 and 1430) are wound around projections1406 and across front side 1401 of frame 1400. In such embodiments,thread lines 1422/1432 of continuous threads 1420/1430 extend betweenrespective projections 1406 on front side 1401 of frame 1400. In someembodiments, one or more continuous threads (e.g., continuous threads1420 and 1430) may be wound around projections 1406 and across frontside 1401 and rear side 1403 of frame 1400. In such embodiments, threadlines 1422/1432 of continuous threads 1420/1430 extend betweenrespective projections 1406 on front side 1401 and rear side 1403 offrame 1400, and may wrap around exterior perimeter wall 1404. For frame1400, projections 1406 define anchor points of thread pattern 1410.

Once a desired thread pattern 1410 is wound (see FIG. 14A), continuousthreads 1420 and 1430 of thread pattern 1410 may be bonded tomechanically set the thread pattern 1410. In some embodiments, threadlines 1422/1432 of continuous threads 1420/1430 may be bonded to frame1400 around projections 1406. In some embodiments, thread lines1422/1432 of continuous threads 1420/1430 may be bonded at together atpoints of intersection between thread lines 1422/1432. Thread lines1422/1432 may be bonded at intersection points via an adhesive, abonding layer, thermal (conductive or convective) heat (e.g., in a heatpress or oven), IR (infrared) heating, laser heating, microwave heating,steam, a mechanical fastener (e.g., a clip), hook and loop fasters,needle-punching, hydro-entanglement, ultrasonic/vibratory entanglement,felting, knotting, or by pushing one thread line through the otherthread line(s). In embodiments including a polymeric continuous thread1420 and/or 1430, the polymeric material(s) of continuous thread 1420and/or 1430 may directly bonded thread lines 1422/1432 at projections1406 and/or at points of intersection between thread lines 1422/1432. Insome embodiments, thread lines 1422/1432 of continuous threads 1420/1430may alternatively or additionally be bonded with a bonding layer asdiscussed herein. In such embodiments, one or more portions of threadlines 1422/1432 within opening 1408 may be bonding with a bonding layer.

Once thread pattern 1410 is mechanically set by bonding continuousthreads 1420 and 1430, thread pattern 1410 may be cut from frame 1400 asshown in FIG. 14B. In some embodiments, a bonding layer may be appliedto thread pattern 1410 after it is cut from frame 1400.

In some embodiments, frame 1400 may be a hand-held frame. In someembodiments, frame 1400 may be attached to a device configured to rotatethe frame (e.g., a lathe). During rotation of frame 1400, continuousthread(s) may be wound around frame 1400 either manually or with acomputer-assisted machine (e.g., a CNC machine). In some embodiments,thread may be wound around frame 1400 while frame 1400 is heldstationary.

FIGS. 15-19 illustrate various bonding layers for bonding continuousthread(s) of thread patterns discussed herein. For purposes ofillustration, FIGS. 15-19 show bonding layers applied to thread patternswatches. However, the bonding layers illustrated in FIGS. 15-19 may beapplied to thread patterns discussed. In some embodiments, multipletypes of bonding layers may be applied to thread patterns discussedherein.

FIG. 15 shows a thread pattern swatch 1500 including a thread pattern1510 and a stitched bonding layer 1520. Stitched bonding layer 1520includes one or more threads stitched to thread pattern 1510. And thethreads of bonding layer 1520 fix thread lines 1512 of thread pattern1510 together by stitching thread lines 1512 to each other. Threads ofbonding layer 1520 may be stitched to thread lines 1512 of threadpattern 1510 using an any suitable stitching process, such as anembroidery process, computer stitching, chain stitching, straightstitching, zigzag stitching, running stitching, back stitching, anddamask stitching (also called satin stitching).

Stitched bonding layer 1520 may include a perimeter portion 1522defining a perimeter shape of stitched bonding layer 1520. When appliedto an upper, perimeter portion 1522 may correspond to a perimeterportion of the upper (e.g., perimeter portion 162 of upper 120). In someembodiments, stitched bonding layer 1520 may include interior threads1524 disposed within perimeter portion 1522. Interior threads 1524provide additional bonding between thread lines 1512 and may increasethe structural rigidity of thread pattern 1510. In some embodiments,interior threads 1524 may bond thread lines 1512 of thread pattern 1510at a plurality of intersection points between thread lines 1512.Alternatively or additionally, interior threads 1524 may impart adesired aesthetic design to thread pattern 1510. In some embodiments,multiple stitched bonding layers 1520 may be used to bond thread pattern1510.

In some embodiments, the material and/or geometry of stitched bondinglayer 1520 at intersection points between stitched bonding layer 1520and thread lines 1512 may be tailored to provide desired characteristicsto a thread pattern. For example, a stitched bonding layer 1520including a high tensile stiffness material (e.g., a nylon thread)stitched through thread lines 1512 may serve to fix thread lines 1512firmly together. In contrast, a stitched bonding layer 1520 including amore flexible thread looped around thread lines 1512 at intersectionpoints between thread lines 1512 and bonding layer 1520 may serve toallow relative movement at the intersection points. Different materialsand/or geometry of stitched bonding layer 1520 in different regions ofstitched bonding layer 1520 may serve to impart differentcharacteristics to different regions of a thread pattern.

FIGS. 16A and 16B show a thread pattern swatch 1600 including threadpattern 1510 and a stitched bonding layer 1620 applied using a removablebacking layer 1630. Similar to stitched bonding layer 1520, stitchedbonding layer 1620 includes one or more threads stitched to thread lines1512 of thread pattern 1510. However, stitched bonding layer 1620 isstitched to thread pattern 1510 by stitching onto removable backinglayer 1630. Removable backing layer 1630 may be a tear away backinglayer or a dissolvable backing layer. In some embodiments, a tear awaybacking layer may be a polyester fabric layer. In some embodiments, adissolvable backing layer may be water soluble fabric layer. FIG. 16Bshows removable backing layer 1630 removed from thread swatch 1600.

Similar to stitched bonding layer 1520, stitched bonding layer 1620 mayinclude a perimeter portion 1622 defining a perimeter shape of stitchedbonding layer 1620. When applied to an upper, perimeter portion 1622 maycorrespond to a perimeter portion of the upper (e.g., perimeter portion162 of upper 120). In some embodiments, stitched bonding layer 1620 mayinclude interior threads 1624 disposed within perimeter portion 1622.Interior threads 1624 provide additional bonding between thread lines1512 and may increase the structural rigidity of thread pattern 1510. Insome embodiments, interior threads 1624 may bond thread lines 1512 ofthread pattern 1510 at a plurality of intersection points between threadlines 1512. Alternatively or additionally, interior threads 1624 mayimpart a desired aesthetic design to thread pattern 1510. In someembodiments, multiple stitched bonding layers 1620 may be used to bondthread pattern 1510.

FIG. 17 shows a thread pattern swatch 1700 including thread pattern 1510and an adhesive bonding layer 1720. Adhesive bonding layer 1720 includesan adhesive disposed on thread lines 1512 of thread pattern 1510. Andadhesive bonding layer 1720 fixes thread lines 1512 of thread pattern1510 to each other by forming an adhesive coating on thread lines 1512.Adhesive bonding layer 1720 may be applied to the inner side or theouter side of thread pattern 1510. In some embodiments, adhesive bondinglayer 1720 may be applied to both the inner and outer sides of threadpattern 1510.

In some embodiments, adhesive bonding layer 1720 may be a sprayedadhesive layer, for example a sprayed latex adhesive or a polyurethaneadhesive or paint. In some embodiments, a sprayed adhesive bonding layermay include a primer and an adhesive. In some embodiments, adhesivebonding layer 1720 may be a semi-dissolved fabric layer. In someembodiments, adhesive bonding layer 1720 may be a semi-dissolved watersoluble adhesive layer. In some embodiments, adhesive bonding layer 1720may be a printed (e.g., screen printed or ink-jet printed) adhesivelayer. In some embodiments, adhesive bonding layer 1720 may be a UV(ultraviolet) cured, IR (infrared) cured, or heat cured adhesive layer.In some embodiments, adhesive bonding layer 1720 may be a tape layer,such as a hemming tape layer. In some embodiments, adhesive bondinglayer 1720 may be a glue layer. In some embodiments, mechanicalcompression may be applied to help adhere adhesive bonding layer 1720 tothread lines 1512 of thread pattern 1510.

In some embodiments, adhesive bonding layer 1720 may be applied overentire thread pattern 1510. In some embodiments, adhesive bonding layer1720 may include a perimeter portion 1722 defining a perimeter shape ofadhesive bonding layer 1720. When applied to an upper, perimeter portion1722 may correspond to a perimeter portion of the upper (e.g., perimeterportion 162 of upper 120). In some embodiments, adhesive bonding layer1720 may include interior members 1724 disposed within perimeter portion1722. Interior members 1724 provide additional bonding between threadlines 1512 and may increase the structural rigidity of thread pattern1510. In some embodiments, interior members 1724 may bond thread lines1512 of thread pattern 1510 at a plurality of intersection pointsbetween thread lines 1512. Alternatively or additionally, interiormembers 1724 may impart a desired aesthetic design to thread pattern1510. Space between perimeter portion 1722 and respective interiormember 1724 is devoid of adhesive bonding layer 1720. In someembodiments, multiple adhesive bonding layers 1720 may be used to bondthread pattern 1510.

In some embodiments, the properties of an adhesive or differentadhesives used for different regions of adhesive bonding layer 1720 maybe tailored to provide different bonding strengths to different regionsof adhesive bonding layer 1720. In such embodiments, the differentbonding strengths at intersections between thread lines 1512 may beutilized to tailor characteristics of a thread pattern. For example,perimeter portion 1722 may be composed of a relatively flexible adhesivelayer and interior members 1724 may be composed of a relatively stiffadhesive layer, or vice versa.

FIG. 18 shows a thread pattern swatch 1800 including thread pattern 1510and a film bonding layer 1820. Film bonding layer 1820 includes a filmdisposed on thread lines 1512 of thread pattern 1510. And film bondinglayer 1820 fixes thread lines 1512 of thread pattern 1510 to each other.Film bonding layer 1820 may be applied to the inner side or the outerside of thread pattern 1510. In some embodiments, film bonding layer1820 may be applied to both the inner and outer sides of thread pattern1510.

In some embodiments, film bonding layer 1820 may be a heat pressedtextile film layer, such as a heat pressed Nylon textile film layer. Insome embodiments, film bonding layer 1820 may be a heat bonded polymericlayer (e.g., a polymeric lamination layer). In some embodiments, filmbonding layer 1820 may be a screen-printed textile film layer. Forexample, film bonding layer 1820 may be a screen-printed Nylon bag inklayer. In some embodiments, film bonding layer 1820 may be ascreen-printed ink layer.

In some embodiments, film bonding layer 1820 may be applied over entirethread pattern 1510. In some embodiments, film bonding layer 1820 mayinclude a perimeter portion 1822 defining a perimeter shape and of filmbonding layer 1820. When applied to an upper, perimeter portion 1822 maycorrespond to a perimeter portion of the upper (e.g., perimeter portion162 of upper 120). In some embodiments, film bonding layer 1820 mayinclude interior members 1824 disposed within perimeter portion 1822.Interior members 1824 provide additional bonding between thread lines1512 and may increase the structural rigidity of thread pattern 1510. Insome embodiments, interior members 1824 may bond thread lines 1512 ofthread pattern 1510 at a plurality of intersection points between threadlines 1512. Alternatively or additionally, interior members 1824 mayimpart a desired aesthetic design to thread pattern 1510. Space betweenperimeter portion 1822 and respective interior member 1824 is devoid offilm bonding layer 1820. In some embodiments, multiple film bondinglayers 1820 may be used to bond thread pattern 1510.

In some embodiments, the properties of a film or different films usedfor different regions of film bonding layer 1820 may be tailored toprovide different bonding strengths to different regions of film bondinglayer 1820. In such embodiments, the different bonding strengths atintersections between thread lines 1512 may be utilized to tailorcharacteristics of a thread pattern. For example, perimeter portion 1822may be composed of a relatively flexible film layer and interior members1824 may be composed of a relatively stiff film layer, or vice versa.

FIG. 19 shows a thread pattern swatch 1900 including thread pattern 1510and a film bonding layer 1920 according to some embodiments. Filmbonding layer 1920 includes a perimeter portion 1922 and circularinterior members 1924 configured to provide additional bonding betweenthread lines 1512 and impart a desired aesthetic design to threadpattern 1510. Space between perimeter portion 1922 and respectiveinterior member 1924 is devoid of film bonding layer 1920.

FIG. 20A shows an image of an article of footwear 2000 made using method200 according to some embodiments. Article of footwear 2000 includesupper 120 coupled to sole 180. Upper 120 includes thread pattern 122 andperimeter portion 162. Thread lines 132 of the continuous threads ofthread pattern 122 have been thermally bonded at anchor points 134 andintersection points 136 via the polymeric material of the continuousthreads. Perimeter portion 162 is a polymeric, laminated bonding layerthat bonds thread lines of thread pattern 122 at perimeter portion 162.And sole 180 is coupled to upper along biteline 160.

FIG. 20B shows an image of an article of footwear 2020 made using method200 according to some embodiments. Article of footwear 2020 includesupper 120 with thread pattern 122 bonded to a fabric layer 172. Threadlines 132 of the continuous threads of thread pattern 122 have beenthermally bonded at intersection points 136. As illustrated in FIG. 20B,no anchor points from the winding process used to make thread pattern122 remain on article of footwear 2020. These anchor points were cutfrom thread pattern 122 after winding.

FIG. 20C shows an image of an article of footwear 2040 made using method200 according to some embodiments. Article of footwear 2040 includesupper 120 with thread pattern 122 and a bonding layer 630. Thread lines132 of the continuous threads of thread pattern 122 have been bonded atintersection points 136. As illustrated in FIG. 20C, no anchor pointsfrom the winding process used to make thread pattern 122 remain onarticle of footwear 2040. These anchor points were cut from threadpattern 122 after winding.

FIG. 21 shows a mold 2100 for molding a sole (e.g., sole 1100) accordingto some embodiments. Mold 2100 includes a first mold plate 2110 and asecond mold plate 2120. Second mold plate 2120 includes a sole cavity2122 having a sole cavity bottom surface 2124 and a sole cavity sidesurface 2126. Sole cavity bottom surface 2124 includes elements 2130 forforming traction elements, such as cleats. In some embodiments, elements2130 may be projections extending from sole cavity bottom surface 2124.In some embodiments, elements 2130 may be indentations in sole cavitybottom surface 2124 configured to receive traction elements, for examplecleat studs. When assembled, first mold plate 2110 and second mold plate2120 form a mold cavity having an interior shape corresponding to theshape of a sole for an article of footwear.

In embodiments including elements 2130 that are projections, threadlines 2132 of one or more continuous threads may be wound aroundelements 2130 in a similar fashion as discussed herein for windingcontinuous thread(s) around pins. In other words, projecting elements2130 may define anchor points for thread lines 2132. In someembodiments, as shown for example in FIG. 21B, elements 2130 may beprojections that are removably attached to sole cavity bottom surface2124. Removable projections 2130 may be attached to sole cavity bottomsurface 2124 via a removable mechanical attachment, such as but notlimited to, a screw attachment or a friction fit. In some embodiments,removable projections 2130 may be removably attached to studs 2125formed on sole cavity bottom surface 2124. In such embodiments, studs2125 may be arranged in a pattern for cleats of an article of footwear.In some embodiments, projections 2130 may include ridges 2131 to helphold threads during winding.

In embodiments including elements 2130 that are indentations, tractionelements (e.g., cleat studs) may be disposed within the indentationssuch that a portion of each stud extends from sole cavity bottom surface2124. In such embodiments, the portion of each stud projecting abovesole cavity bottom surface 2124 defines an anchor point for windingthread lines 2132. And thread lines 2132 of one or more continuousthreads may be wound around the projecting portion of the studs asimilar fashion as discussed herein for winding continuous thread(s)around pins.

After winding thread lines around projecting elements 2130 or projectingportions of cleat studs, sole material may be disposed within solecavity 2122 and a sole may be molded around thread lines 2132 withinmold 2100. In other words, thread lines 2132 may be encased with a solematerial defining at least a portion of a sole (e.g., sole 1100). Insome embodiments, mold 2100 may be an injection molding mold. In someembodiments, mold 2100 may be used to partially consolidate a sole andthe sole may be cured to fully solidify the sole. After molding, thesole may be removed from mold 2100. In embodiments including removableprojections 2130 or traction elements, sole material may be bonded toremovable projections 2130 or traction elements during molding.

FIGS. 22A-C illustrate a method of molding a sole 2200 according to someembodiments. As shown in FIG. 22A, removable projections 2130 may beattached to studs 2125 of second mold plate 2120. After attachingremovable projections 2130, thread lines 2132 of one or more continuousthreads may be wound around projections 2130 as discussed herein. And,after winding, first mold plate 2110 may be disposed over second moldplate 2120 and sole material 2140 may be injected into the cavity formedbetween first mold plate 2110 and second mold plate 2120, as shown inFIG. 22B. The injection of sole material 2140 into the mold cavity mayembed thread lines 2132 within sole material 2140.

While in the mold cavity, sole material 2140 may be fully or partiallysolidified, e.g., by curing sole material 2140. Also, while in the moldcavity, mold material 2140 may bond to removable projections 2130 and/orthread lines 2132. After fully or partially curing sole material 2140, afully or partially solidified sole 2200 may be removed from the moldcavity with removable projections 2130 forming a portion of cleats 2202for sole 2200.

While various embodiments have been discussed herein in the context offootwear, other articles of apparel may be manufactured using thewinding processes discussed herein. Other articles of apparel include,but are not limited to, pants, shorts, leggings, a sock, a jacket, acoat, a hat, a sleeve, a shoe, a sweater, a shirt, a jersey, a bra, abootie, and a glove.

FIGS. 25A-25F illustrate various methods for bonding thread lines 2500according to some embodiments. FIG. 25A illustrates a method of bondingthread lines 2500 using an adhesive sheet 2502 that is dissolvable.Adhesive dissolvable sheet 2502 is applied to thread lines 2500 and isthen dissolved. Thread lines 2500 are adhered together at locationswhere sheet 2502 is dissolved. The dissolution process can be stopped atdifferent levels, leaving different amounts of dissolved and undissolvedadhesive behind.

FIG. 25B illustrates a method of bonding thread lines 2500 via stitching2504. Stitching 2504 is stitched to thread lines 2500 in selectedplaces, using for example a sewing machine. Stitching 2504 may bestitched in selected places to locally fix thread lines 2500 together.In some embodiments, this approach may include the use of a backingsheet 2506 as a substrate to assist with the sewing process. In suchembodiments, thread lines 2500 are sewn onto backing sheet 2506. Andafter sewing, backing sheet 2506 is removed, for example by dissolvingbacking sheet 2506. If thread lines 2500 form a dense enough threadpattern, backing sheet 2506 may not be required.

FIG. 25C illustrates a method of bonding thread lines 2500 via stitching2504. Stitching 2504 is stitched to thread lines 2500 in selectedplaces, using for example a sewing machine. Stitching 2504 may bestitched in selected places to locally fix thread lines 2500 together.In some embodiments, this approach may include the use of a backingsheet 2508 as a substrate to assist with the sewing process. In suchembodiments, thread lines 2500 are sewn onto backing sheet 2508. Andafter sewing, backing sheet 2508 is removed, for example, by tearing orcutting backing sheet 2508 away. If thread lines 2500 form a denseenough thread pattern, backing sheet 2508 may not be required.

FIG. 25D illustrates a method of bonding thread lines 2500 using localstitches 2510. Local stitches 2510 may be stitched using a sewingmachine. In this process, thread lines 2500 are stitched together arespecific points in a thread pattern. For example, a first stitch 2510may locally bond one or more thread lines 2500 at a first point, thenthe thread of the stitch is run at a desired trajectory to a secondpoint where a second stitch 2510 locally bonds one or more thread lines2500. This technique is repeated until the bonding of thread lines 2500is completed, with local stitches 2510 acting as the structure thatbonds thread lines 2500 together. In some embodiments, a backing sheet(e.g., a dissolvable sheet, tear-away sheet, or a non-dissolvable ornon-tear-way fabric layer) may be used to as a substrate to assist withthe sewing process.

FIG. 25E illustrates a method of spraying an adhesive to bond threadlines 2500. Sprayed adhesive can be selectively applied to desiredlocations on a thread pattern by, for example, a mask 2512 or alocation-controlled spray nozzle.

FIG. 25F illustrates a method of spraying an activated adhesive to bondthread lines 2500. This technique uses an adhesive to consolidate athread pattern. The adhesive is applied to the thread pattern and isthen activated at desired regions to consolidate the thread pattern.Activation of the adhesive may solidify the adhesive, for example bycuring the adhesive. This activation can use, for example, light,temperature or a chemical accelerator/activator. In some embodiments, amask 2512 may be utilized to control activation in selected regions ofthe thread pattern by blocking activation energy in selected regions.After activation, any excess adhesive may be removed from the threadpattern.

FIG. 25G illustrates a method of adhesively bonding thread lines 2500 oftwo thread pattern layers together. This technique uses an adhesive tofix thread lines 2500 of different thread patterns together, therebyconsolidating the thread patterns. Adhesive is applied to a first threadpattern layer and a second thread pattern layer is disposed over theadhesive coated surface of the first thread pattern layer. This processmay be repeated depending on how may thread pattern layers are desired.In some embodiments, pressure may be applied to press the thread patternlayers against each other and aid in bonding the thread pattern layerstogether.

FIG. 25H illustrates a method of thermally bonding thread lines 2500. Inthis technique, thread lines 2500 are coated in a material which allowsthread lines 2500 to be directly bonded to each other with theapplication of heat and/or pressure. The material coated on thread lines2500 may be, for example, a thermoplastic polymer or a heat-activatedadhesive. Consolidation is achieved by heat pressing a thread pattern ina heat press 2514 in order to bond thread lines 2500 at intersectionpoints and/or where they are in close proximity to each other.Structured press plates or a localized heat source may be used toconsolidate the thread pattern in only selected areas.

FIG. 25I illustrates a method of screen-printing a material to bondthread lines 2500. In this technique, a thread pattern is consolidatedby screen printing, for example, an adhesive or ink onto thread lines2500. The screen-printed material is applied to thread lines 2500through a mask 2516. The screen-printed material may be cured after itis printed on thread lines 2500.

FIG. 25J illustrates a method of bonding thread lines 2500 using an inkjet printer 2518. In this technique, a thread pattern is consolidated byink-jet printing an adhesive or ink onto the thread pattern at specificlocations. The ink-jet printed material may be cured after it is printedon thread lines 2500.

FIG. 25K illustrates a method of bonding thread lines 2500 using astructured backing sheet 2520. In this technique, a thread pattern isconsolidated by attaching structured backing sheet 2520 to the threadpattern. Structured backing sheet 2520 includes apertures 2522 in areaswhere thread lines 2500 are not intended to be bonded together. Backingsheet 2520 may be attached to the thread pattern using, for example, anadhesive or heat bonding.

FIG. 25L illustrates a method of bonding thread lines 2500 using anadhesive 2524 deposited on a transfer tape 2526. Transfer tape 2526 isused to transfer adhesive 2524 onto the thread pattern. The substrate ofthe transfer tape 2526 is removed leaving behind only adhesive 2524bonding thread lines 2500 together.

FIG. 25M illustrates a method of bonding thread lines 2500 using acoated thread 2528. A coating 2530 is applied to thread 2528 locally asit is applied to the thread pattern. Coating 2530 may be, for example,an ink or adhesive coating. Coating 2530 is only applied in areas wherethread lines 2500 are intended to be bonded together. Since the patternof a given thread pattern is known prior to applying thread 2528,coating 2530 may be applied to thread 2528 at desired locations forbonding thread lines 2500. For example, coating 2530 may be applied tothread 2528 at specific locations such that when thread 2528 is appliedto or wound as a thread in a thread pattern, coating 2530 is located atintersection points between thread lines 2500.

FIG. 25N illustrates a method of bonding thread lines 2500 using acoated thread 2532 as a continuous thread within a thread pattern. Sincea thread model may be used to determine a thread pattern, as discussedherein, the routing and patterning of a thread pattern may be determinedprior to a winding process. As such, it is also determined whereintersection points between individual thread lines will occur along thelength of any thread within the pattern. Accordingly, one or more coatedthreads 2532 may be prepared to have a coating 2534 deposited atintersection points at which thread lines are intended to be bondedtogether. Coated thread(s) 2532 may be selectively coated with coating2534, wound onto a spool, and then wound around anchor points of athread pattern, as discussed herein. In some embodiments, coating 2534may bond thread lines 2500 at an intersection point with coating 2534 ofcoated thread 2532 without any external influence. In some embodiments,coating 2534 may be activated using, for example, light, heat, and/orchemical activation. In some embodiments, coated thread 2532 may beapplied to thread pattern, rather than wound as a continuous threadwithin the thread pattern.

One or more aspects of the methods of manufacturing an article offootwear discussed herein, or any part(s) or function(s) thereof (e.g.,collecting biometric data, generating thread models based on biometricdata, and winding continuous threads with a CNC machine based on athread model), may be implemented using hardware, software modules,firmware, tangible computer readable media having instructions storedthereon, or a combination thereof and may be implemented in one or morecomputer systems or other processing systems.

FIG. 26 illustrates an exemplary computer system 2600 in whichembodiments, or portions thereof, may be implemented ascomputer-readable code. For example, aspects of the methods discussedherein that may be implemented in one or more computer systems include,but are not limited to, collecting a biometric data profile, generatingpolymer thread patterns based on the biometric data profile, andobtaining an already generated polymer thread pattern (or patterns) maybe implemented in computer system 2600 using hardware, software,firmware, tangible computer readable media having instructions storedthereon, or a combination thereof and may be implemented in one or morecomputer systems or other processing systems.

If programmable logic is used, such logic may execute on a commerciallyavailable processing platform or a special purpose device. One ofordinary skill in the art may appreciate that embodiments of thedisclosed subject matter can be practiced with various computer systemconfigurations, including multi-core multiprocessor systems,minicomputers, and mainframe computers, computer linked or clusteredwith distributed functions, as well as pervasive or miniature computersthat may be embedded into virtually any device.

For instance, at least one processor device and a memory may be used toimplement the above described embodiments. A processor device may be asingle processor, a plurality of processors, or combinations thereof.Processor devices may have one or more processor “cores.”

Various embodiments of the inventions may be implemented in terms ofthis example computer system 2600. After reading this description, itwill become apparent to a person skilled in the relevant art how toimplement one or more of the inventions using other computer systemsand/or computer architectures. Although operations may be described as asequential process, some of the operations may in fact be performed inparallel, concurrently, and/or in a distributed environment, and withprogram code stored locally or remotely for access by single ormulti-processor machines. In addition, in some embodiments the order ofoperations may be rearranged without departing from the spirit of thedisclosed subject matter.

Processor device 2604 may be a special purpose or a general purposeprocessor device. As will be appreciated by persons skilled in therelevant art, processor device 2604 may also be a single processor in amulti-core/multiprocessor system, such system operating alone, or in acluster of computing devices operating in a cluster or server farm.Processor device 2604 is connected to a communication infrastructure2606, for example, a bus, message queue, network, or multi-coremessage-passing scheme.

Computer system 2600 also includes a main memory 2608, for example,random access memory (RAM), and may also include a secondary memory2610. Secondary memory 2610 may include, for example, a hard disk drive2612, or removable storage drive 2614. Removable storage drive 2614 mayinclude a floppy disk drive, a magnetic tape drive, an optical diskdrive, a flash memory, a Universal Serial Bus (USB) drive, or the like.The removable storage drive 2614 reads from and/or writes to a removablestorage unit 2618 in a well-known manner. Removable storage unit 2618may include a floppy disk, magnetic tape, optical disk, etc. which isread by and written to by removable storage drive 2614. As will beappreciated by persons skilled in the relevant art, removable storageunit 2618 includes a computer usable storage medium having storedtherein computer software and/or data.

Computer system 2600 (optionally) includes a display interface 2602(which can include input and output devices such as keyboards, mice,etc.) that forwards graphics, text, and other data from communicationinfrastructure 2606 (or from a frame buffer not shown) for display ondisplay unit 2630.

In additional and/or alternative implementations, secondary memory 2610may include other similar means for allowing computer programs or otherinstructions to be loaded into computer system 2600. Such means mayinclude, for example, a removable storage unit 2622 and an interface2620. Examples of such means may include a program cartridge andcartridge interface (such as that found in video game devices), aremovable memory chip (such as an EPROM, or PROM) and associated socket,and other removable storage units 2622 and interfaces 2620 which allowsoftware and data to be transferred from the removable storage unit 2622to computer system 2600.

Computer system 2600 may also include a communication interface 2624.Communication interface 2624 allows software and data to be transferredbetween computer system 2600 and external devices. Communicationinterface 2624 may include a modem, a network interface (such as anEthernet card), a communication port, a PCMCIA slot and card, or thelike. Software and data transferred via communication interface 2624 maybe in the form of signals, which may be electronic, electromagnetic,optical, or other signals capable of being received by communicationinterface 2624. These signals may be provided to communication interface2624 via a communication path 2626. Communication path 2626 carriessignals and may be implemented using wire or cable, fiber optics, aphone line, a cellular phone link, an RF link or other communicationchannels.

In this document, the terms “computer program medium” and “computerusable medium” are used to generally refer to media such as removablestorage unit 2618, removable storage unit 2622, and a hard diskinstalled in hard disk drive 2612. Computer program medium and computerusable medium may also refer to memories, such as main memory 2608 andsecondary memory 2610, which may be memory semiconductors (e.g. DRAMs,etc.).

Computer programs (also called computer control logic) are stored inmain memory 2608 and/or secondary memory 2610. Computer programs mayalso be received via communication interface 2624. Such computerprograms, when executed, enable computer system 2600 to implement theembodiments as discussed herein. In particular, the computer programs,when executed, enable processor device 2604 to implement the processesof the embodiments discussed here. Accordingly, such computer programsrepresent controllers of the computer system 2600. Where the embodimentsare implemented using software, the software may be stored in a computerprogram product and loaded into computer system 2600 using removablestorage drive 2614, interface 2620, and hard disk drive 2612, orcommunication interface 2624.

Embodiments of the inventions also may be directed to computer programproducts comprising software stored on any computer useable medium. Suchsoftware, when executed in one or more data processing device, causes adata processing device(s) to operate as described herein. Embodiments ofthe inventions may employ any computer useable or readable medium.Examples of computer useable mediums include, but are not limited to,primary storage devices (e.g., any type of random access memory),secondary storage devices (e.g., hard drives, floppy disks, CD ROMS, ZIPdisks, tapes, magnetic storage devices, and optical storage devices,MEMS, nanotechnological storage device, etc.).

Some embodiments are directed to a method of making an upper for anarticle of footwear, the method including defining a plurality ofperipheral anchor points; winding a continuous thread around theplurality of peripheral anchor points to form a thread pattern, thecontinuous thread including a plurality of thread lines with each threadline extending between two respective peripheral anchor points; andbonding the continuous thread at a point of intersection between thethread lines.

In any of the various embodiments discussed herein, the method of makingan upper may include bonding a continuous thread at one or moreperipheral anchor points.

In any of the various embodiments discussed herein, the method of makingan upper may include bonding a continuous thread at a plurality ofpoints of intersection between thread lines.

In any of the various embodiments discussed herein, the peripheralanchor points may be defined by pins coupled to and extending from a pinassembly plate, and the pins may be configured to support a continuousthread during winding. In any of the various embodiments discussedherein, the peripheral anchor points may be defined by pins coupled toand extending from a three-dimensional object, and the pins may beconfigured to support a continuous thread during winding.

In any of the various embodiments, discussed herein, a thread patternmay be based on a biometric data profile for an individual.

In any of the various embodiments discussed herein, peripheral anchorpoints may have a thread line communication number of three or more. Insome embodiments, the thread line communication number for peripheralanchor points may be based on a biometric data profile for anindividual.

In any of the various embodiments discussed herein, the method of makingan upper may include winding a second continuous thread around aplurality of peripheral anchor points, the second continuous threadincluding a plurality of thread lines with each thread line extendingbetween two respective peripheral anchor points.

In any of the various embodiments discussed herein, the method of makingan upper may include defining a plurality of interior anchor pointsdisposed between a plurality of peripheral anchor points and winding thecontinuous thread around the plurality of interior anchor points.

In any of the various embodiments discussed herein, the method of makingan upper may include bonding thread lines together at a perimeterportion of thread pattern, the perimeter portion including a framehaving a shape corresponding to a least a portion of a perimeter shapeof an upper. In some embodiments, bonding thread lines may include atleast one of: a lamination process, a stitching process, heat pressing,an adhesive bonding process, a screen printing process, and a curingprocess. In some embodiments, the method of making any upper may includeremoving excess thread pattern from an exterior side of the perimeterportion of the thread pattern. In some embodiments, bonding theperimeter portion of the thread pattern may encase a plurality ofperipheral anchor points within a bonding layer.

Some embodiment are directed to a method of making an upper for anarticle of footwear, the method including winding a continuous threadaround a set of pins to form a thread pattern, the pins being coupled toand extending from a support structure and disposed at locationscorresponding to a perimeter of the upper, and the continuous threadincluding a plurality of thread lines, where each thread line extendsbetween two respective pins; and bonding the continuous thread to itselfat one or more of the plurality of pins.

In any of the various embodiments discussed herein, winding and bondingof the thread pattern may be performed without a base layer disposedbetween the thread pattern and a support structure.

In any of the various embodiments discussed herein, the supportstructure may include a support plate. In any of the variousembodiments, discussed herein, the support structure may include a last.

In any of the various embodiments discussed herein, the method of makingan upper may include bonding thread lines together at a perimeterportion of the thread pattern. In some embodiments, the method mayinclude removing excess thread pattern from an exterior side of theperimeter portion.

Some embodiments are directed to an article of footwear including asole; and an upper coupled to the sole, the upper including a pluralityof anchor points disposed along a perimeter of the upper, and acontinuous thread fixed at the plurality of anchor points and includinga plurality of thread lines with each thread line extending between tworespective anchor points, where the anchor points have a thread linecommunication number of three or more, and where the continuous threadis bonded at the plurality of anchor points.

In any of the various embodiments discussed herein, a continuous threadmay be wrapped around a plurality of anchor points.

In any of the various embodiments discussed herein, a continuous threadmay include overlaying thread lines.

In any of the various embodiments discussed herein, an article offootwear may include a plurality of interior anchor points disposedbetween anchor points disposed along the perimeter of an upper, and theinterior anchor points may have a thread line communication number ofthree or more.

In any of the various embodiments discussed herein, an article offootwear may include a bonding layer disposed along a perimeter of theupper and attached to a plurality of anchor points disposed along theperimeter of the upper.

In any of the various embodiments discussed herein, a continuous threadmay include a polymer thread.

In any of the various embodiments discussed herein, an upper may includea second continuous thread fixed at a plurality of anchor points andincluding a plurality of thread lines, with each thread line extendingbetween two respective anchor points, and wherein the anchor points havea thread line communication number for the second continuous thread ofthree or more.

In any of the various embodiments discussed herein, a sole may include aplurality of sole anchor points and a second continuous thread may befixed at the plurality of sole anchor points, the second continuousthread including thread lines extending between two respective soleanchor points. In some embodiments, the second continuous thread may beencased within a material defining at least a portion of the sole. Insome embodiments, the sole may include a plurality of cleats and alocation of one or more of the sole anchor points corresponds to alocation of a cleat.

Some embodiments are directed to an article of footwear including asole; and an upper coupled to the sole, the upper including a perimeterlayer including an outer edge and an inner edge, a first plurality ofthread line groups including three or more thread lines extendingradially from respective areas on the outer edge, and a second pluralityof thread line groups including three or more thread lines extendingradially from respective areas on the inner edge, where the thread linesof the first plurality of thread line groups and the thread lines of thesecond plurality of thread line groups are bonded to each other atpoints of intersection between the thread lines.

In some embodiments, the thread lines of the first plurality of threadline groups and the thread lines of the second plurality of thread linegroups are bonded to the perimeter layer.

Some embodiments are directed to a method of making an article offootwear, the method including winding a continuous thread around a setof pins to form a thread pattern for an upper of the article offootwear, the pins coupled to and extending from a support structure anddisposed at locations corresponding to a perimeter of the upper, and thecontinuous thread comprising a plurality of thread lines, where eachthread line extends between two respective pins; and bonding thecontinuous thread to itself at one or more of the plurality of pins.

In some embodiments, a method of making an article of footwear mayinclude coupling an upper to a sole, the sole made by a processincluding winding a second continuous thread around a plurality ofanchor points defined by projections removably attached to a surface ofa mold cavity and molding a sole material around the second continuousthread and the projections in the mold cavity.

It is to be appreciated that the Detailed Description section, and notthe Summary and Abstract sections, is intended to be used to interpretthe claims. The Summary and Abstract sections may set forth one or morebut not all exemplary embodiments of the present invention(s) ascontemplated by the inventor(s), and thus, are not intended to limit thepresent invention(s) and the appended claims in any way.

The present invention(s) have been described above with the aid offunctional building blocks illustrating the implementation of specifiedfunctions and relationships thereof. The boundaries of these functionalbuilding blocks have been arbitrarily defined herein for the convenienceof the description. Alternate boundaries can be defined so long as thespecified functions and relationships thereof are appropriatelyperformed.

The foregoing description of the specific embodiments will so fullyreveal the general nature of the invention(s) that others can, byapplying knowledge within the skill of the art, readily modify and/oradapt for various applications such specific embodiments, without undueexperimentation, without departing from the general concept of thepresent invention(s). Therefore, such adaptations and modifications areintended to be within the meaning and range of equivalents of thedisclosed embodiments, based on the teaching and guidance presentedherein. It is to be understood that the phraseology or terminologyherein is for the purpose of description and not of limitation, suchthat the terminology or phraseology of the present specification is tobe interpreted by the skilled artisan in light of the teachings andguidance.

The breadth and scope of the present invention(s) should not be limitedby any of the above-described exemplary embodiments, but should bedefined only in accordance with the following claims and theirequivalents.

What is claimed is:
 1. A method of making an upper for an article offootwear, the method comprising: winding a continuous thread around aplurality of peripheral anchor points coupled to a support plate to forma thread pattern, the continuous thread comprising a plurality of threadlines with each thread line extending between two respective peripheralanchor points, and wherein the peripheral anchor points have a threadline communication number of three or more; bonding the continuousthread at a point of intersection between two or more of the threadlines; and after bonding the continuous thread, removing the threadpattern from the support plate and shaping the thread pattern into ashape for at least a portion of the upper.
 2. The method of claim 1,comprising bonding the continuous thread at one or more of the pluralityof peripheral anchor points.
 3. The method of claim 1, comprisingbonding the continuous thread at a plurality of points of intersectionbetween the thread lines.
 4. The method of claim 1, wherein the threadpattern is based on a biometric data profile for an individual.
 5. Themethod of claim 1, wherein the peripheral anchor points have a threadline communication number of five or more.
 6. The method of claim 1,comprising winding a second continuous thread around the plurality ofthe peripheral anchor points in a second thread pattern different fromthe first thread pattern, the second continuous thread comprising aplurality of thread lines with each thread line extending between tworespective peripheral anchor points.
 7. The method of claim 1,comprising defining a plurality of interior anchor points disposedbetween the plurality of peripheral anchor points; and winding thecontinuous thread around the plurality of interior anchor points.
 8. Themethod of claim 1, comprising bonding thread lines together at aperimeter portion of the thread pattern, the perimeter portioncomprising a frame having a shape corresponding to a least a portion ofa perimeter shape of the upper.
 9. The method of claim 8, comprisingremoving excess thread pattern from an exterior side of the perimeterportion.
 10. The method of claim 8, wherein bonding the perimeterportion comprises encasing a plurality of the peripheral anchor pointswithin a bonding layer.
 11. The method of claim 1, wherein the supportplate comprises a front side, a rear side, and a perimeter wall, andwherein the plurality of peripheral anchor points extend from theperimeter wall of the support plate.
 12. The method of claim 11, whereinwinding the continuous thread around the plurality of peripheral anchorpoints comprises: wrapping the continuous thread around a firstperipheral anchor point, threading the continuous thread across thefront side of the support plate from the first peripheral anchor pointto a second peripheral anchor point, wrapping the continuous threadaround the second peripheral anchor point, threading the continuousthread across the front side of the support plate from the secondperipheral anchor point to a third peripheral anchor point, and wrappingthe continuous thread around the third peripheral anchor point.
 13. Themethod of claim 6, wherein bonding the continuous thread furthercomprises bonding a thread line of the first thread pattern to a threadline of the second thread pattern at a point of intersection between thethread line of the first thread pattern and the thread line of thesecond thread pattern.
 14. The method of claim 1, wherein bonding thecontinuous thread at the point of intersection between the two or morethread lines comprises directly bonding a first thread line to a secondthread line via a polymeric material of the continuous thread.
 15. Amethod of making an article of footwear, the method comprising: windinga continuous thread around a set of projections to form a thread patternfor an upper of the article of footwear, the projections coupled to andextending from a support plate and disposed at locations correspondingto a perimeter portion of the upper, and the continuous threadcomprising a plurality of thread lines, wherein each thread line extendsbetween two respective projections; bonding the continuous thread toitself at one or more of the plurality of projections; and after bondingthe continuous thread, removing the thread pattern from the supportplate, shaping the thread pattern into a shape for at least a portion ofthe upper, and attaching the perimeter portion of the upper to a sole ata biteline of the article of footwear.
 16. The method of claim 15,wherein the winding and bonding are performed without a base layerdisposed between the thread pattern and the support structure.
 17. Themethod of claim 15, further comprising bonding thread lines together atthe perimeter portion of the upper.
 18. The method of claim 17,comprising removing excess thread pattern from an exterior side of theperimeter portion.
 19. The method of claim 15, wherein the sole is madeby a process comprising: winding a second continuous thread around aplurality of anchor points defined by projections removably attached toa surface of a mold cavity, and molding a sole material around thesecond continuous thread and the projections in the mold cavity.
 20. Themethod of claim 15, wherein the plurality of projections comprise afirst projection disposed at a location corresponding to a medial sideof the perimeter portion of the upper and a second projection disposedat a location corresponding to a lateral side of the perimeter portionof the upper, and wherein one of the thread lines extends between thefirst projection and the second projection.